Aqueous dispersion type thermosetting coating composition

ABSTRACT

Disclosed in an aqueous dispersion type thermosetting coating composition which comprises fine thermosetting resin particles composed of (A) a polyester resin having a specific hydroxyl value and (B) a copolymer resin, which are dispersed in the presence of (C) a surface active agent and/or a thickener in (D) a necessary amount of water.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to a novel aqueous dispersion typethermosetting coating composition. More particularly, the presentinvention relates to an aqueous dispersion type thermosetting coatingcomposition which is excellent in storage stability and free ofyellowing and which provides a coating excellent in gloss, smoothness,flash rusting prevention, corrosion resistance and water resistancewithout such defects and popping when it is baking temperatures of arelatively broad range.

(2) Description of the Prior Art

Recently, development of paints and coating methods causing noenvironmental pollution has been desired, and the use of powdery paintsand aqueous paints has been expanding steadily. These paints haveimportant characteristics and merits, but they still include variousdefects and disadvantages as well.

More specifically, the use of powdery paints involves variousdifficulties. For example, special coating equipment must be used forperforming the coating operation using powdery paints, and hence, theadaptability of powdery paints to the coating operation is much lowerthan that of conventional solvent type paints. Moreover, coatings formedfrom these powdery paints are inferior in smoothness and appearance, andit is difficult to form thin coating films having a thickness smallerthan 50μ.

In the field of aqueous paints of the water-soluble type, since it isimpossible to form paints having a high solid concentration, it isimpossible to form thick coatings by one coating operation. Furthermore,because of the presence of a number of hydrophilic groups introduced torender the base resin water-soluble, the durability of the resultingcoatings is very poor.

Paints of the aqueous dispersion type, called "latex paints" or"emulsion paints" have long been known (see, for example, U.S. Pat. No.2,904,523, No. 2,994,676, No. 3,002,940, No. 3,025,252, No. 3,170,888,No. 3,244,542, No. 3,657,175, No. 3,687,885, No. 3,839,254 and No.3,926,874). In these aqueous latex or emulsion paints, since surfaceactive agents are used in large quantities, the resulting coatings areinsufficient in water resistance, chemical resistance and the like.

As paints overcoming these defects and disadvantages, there have beendeveloped slurry paints (aqueous dispersion type paints) which areformed by suspending a powdery resin in water and are used in the samemanner as aqueous paints.

Paints of this type comprise an aqueous dispersion medium and aparticulate resin having a size of about 0.5 to about 80μ, which isdispersed in the aqueous medium at a solid concentration of 20 to 70% byweight.

As the coating method for these slurry paints, there can be mentioned,for example, a method in which the paint is spray-coated on the surfaceof an article to be coated, water is evaporated and the resin componentis cured to form a coating (see U.S. Pat. No. 3,787,230) and a method inwhich an aqueous dispersion of particles of a nylon resin isspray-coated on an article maintained at a temperature higher than 100°C. to form a coating (see U.S. Pat. No. 2,972,552). As known paints tobe used for these coating methods, there can be mentioned, for example,(i) a paint comprising particles of a chlorinated polyester resin havinga size smaller than 200 mesh, which are dispersed in water (see U.S.Pat. No. 3,089,783), (ii) a paint comprising particles of a chlorinatedpolyester polymer dispersed in water containing a surface active agent,an ester of a polyhydric alcohol with a lower aliphatic monocarboxylicacid, an alkaline water softener and a lower aliphatic alcohol (see U.S.Pat. No. 3,446,652), (iii) a slurry paint comprising particles of aresin selected from acrylic resins, epoxy resins, polyester resins,amino resins and polyurethane resins and a water-soluble thickener (seeU.S. Pat. No. 3,907,737), (iv) a slurry paint comprising as the binderparticles of a powder thermosetting acrylic resin (see U.S. Pat. No.3,904,795), (v) a slurry paint comprising a reactive flow adjustingagent having a specific structure (see U.S. Pat. No. 4,122,055) and (vi)a slurry paint comprising an aqueous medium, resin particles having asize of 0.5 to 80μ and an aluminum pigment (see British Pat. No.1,517,834).

As the process for preparing these slurry paints, there are known aprocess comprising dissolving a resin in a water-soluble solvent, forexample, an alcohol such as methanol or ethanol, a ketone such asacetone or diacetone alcohol, an ester such as ethyl lactate or ethyleneglycol monomethyl ether acetate or an ether such as ethylene glycolmonoethyl ether, and adding the resulting solution to water beingagitated at a high speed to precipitate resin particles in water (seeU.S. Pat. No. 3,737,401), and a process comprising pulverizing a solidresin according to an ordinary pulverization method and dispersing thepulverized resin in water.

Slurry paints prepared according to these processes are characterized inthat they can be applied at a solid concentration as high as about 40 toabout 60% by weight, the coating operation can be accomplished by usinga conventional coating apparatus for solvent dilution type paints andthe only volatile component contained in the paint is the water that isused as the dispersion medium. Furthermore, since this aqueousdispersion medium contains no soluble component, conserving of resourcescan be attained and environmental pollution can be prevented. Because ofthese advantages and merits, it is expected that demands for paints ofthis type will increase remarkably from now on.

As the resin component that is used for these slurry paints, there areknown acrylic resins, polyester resins, epoxy resins and alkyd resins.From the viewpoints of storage stability of paints and smoothness andfinish appearance of the resulting coatings, acrylic resins andpolyester resins are considered preferable among these resins. Accordingto the type of the cross-linking reaction, these resins are classifiedas self-curing resins and resins cross-linkable with the aid of across-linking agent or curing agent. As the cross-linking or curingagent, there have heretofore been used melamine resins and blockedisocyanate compounds. Furthermore, epoxy resins are sometimes used incombination with such cross-linking or curing agents so as to improvethe corrosion resistance.

When slurry paints comprising a melamine resin as the cross-linkingagent are used, in case of thick coatings, popping is caused at thebaking step and the adaptability to the coating workability is poor. Inthis case, therefore, the coating operation should be repeated severaltimes to obtain a coating which is as thick as desired. The combined useof such melamine resin with a urethane (blocked isocyanate compound) hasbeen proposed as means for preventing popping, but this proposal isdefective in that yellowing is readily caused when baking is carried outat a high temperature (see Japanese Patent Application Laid-OpenSpecifications No. 112428/75 and No. 108433/77).

Since slurry paints comprise water as the dispersion medium, if they aredirectly applied to an iron plate such as a soft steel plate, as in thecase of conventional aqueous paints, an undesirable phenomenon of flashrusting which is not observed in solvent type paints, is caused. Inorder to prevent this undesirable phenomenon, a flash rusting-preventingagent or the like is frequently incorporated into slurry paints as inthe case of aqueous paints. However, the storage stability or the likeis adversely affected by the use of such flash rusting-preventing agentand the use of such flash rusting-preventing agent is not preferred.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a novel aqueous dispersion typethermosetting coating composition. More particularly, the presentinvention provides an aqueous dispersion type thermosetting coatingcomposition which is excellent in storage stability and free ofyellowing and which produces a coating excellent in gloss, smoothness,flash rusting prevention, corrosion resistance and water resistancewithout such defects as popping when it is baked at baking temperaturesof a relatively broad range.

The aqueous dispersion type thermosetting coating composition accordingto the present invention comprises fine thermosetting resin particlescomposed of (A) a polyester-modified vinyl resin having a specifichydroxyl value, which is formed by graft-polymerizing (i) an unsaturatedpolyester resin with (ii) an α,β-monoethylenically unsaturated monomerand, if necessary, with (iii) an α-β, monoethylenically unsaturatedmonomer containing a phosphoric acid group and (B) a cross-linkablecopolymer resin derived from a mixture containing (iv) anN-alkoxymethylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid amide, said fine resin particles being dispersed in thepresence of (C) a surface active agent and/or a thickener in (D) anecessary amount of water.

In accordance with another embodiment of the present invention, there isprovided an aqueous dispersion type thermosetting coating compositioncomprising fine thermosetting resin particles composed of (A) apolyester-modified vinyl resin having a specific hydroxyl value, whichis formed by graft-polymerizing (i) an unsaturated polyester resin witha monomer mixture containing (iv) an N-alkoxymethylated monomer of an α,β-monoethylenically unsaturated carboxylic acid amide and (B) aphosphoric acid group-containing copolymer derived from a monomermixture containing (iii) an α,β-monoethylenically unsaturated monomercontaining a phosphoric acid group, said fine resin particles beingdispersed in the presence of (C) a surface active agent and/or athickener in (D) a necessary amount of water.

More specifically, in accordance with one fundamental aspect of thepresent invention, there is provided an aqueous dispersion typethermosetting coating composition [I] comprising a fine thermosettingresin particles composed of (A) 5 to 90% by weight of apolyester-modified vinyl resin having a hydroxyl value of 30 to 200,which is formed by graft-polymerizing (i) 5 to 50% by weight of anunsaturated polyester resin with (ii) 95 to 50% by weight of at leastone α,β-monoethylenically unsaturated monomer and (B) 95 to 10% byweight of a cross-linkable copolymer resin derived from a monomermixture comprising (iv) an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide and (ii) atleast one α,β-monoethylenically unsaturated monomer, (C) a surfaceactive agent and/or a thickener in an amount of 0.01 to 1.0% by weightbased on said resin particles and (D) a necessary amount of water.

In accordance with another fundamental aspect of the present invention,there is provided an aqueous dispersion type thermosetting coatingcomposition [II] comprising fine thermosetting resin particles composedof (A) 5 to 90% by weight of a polyester-modified vinyl resin having ahydroxyl value of 30 to 200, which is formed by graft-polymerizing (i) 2to 50% by weight of an unsaturated polyester resin with (ii) 95 to 40%by weight of at least one α,β-monoethylenically unsaturated monomer and(iii) 0.01 to 10% by weight of an α,β-monoethylenically unsaturatedmonomer containing a phosphoric acid group and (B) 95 to 10% by weightof a cross-linkable copolymer resin derived from a monomer mixturecomprising (iv) an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide and (ii) atleast one α,β-ethylenically unsaturated monomer, (C) a surface activeagent and/or a thickener in an amount of 0.01 to 1.0% by weight based onsaid resin particles and (D) a necessary amount of water.

In accordance with still another fundamental aspect of the presentinvention, there is provided an aqueous dispersion type thermosettingcoating composition [III] comprising fine thermosetting resin particlescomposed of (A) 15 to 95% by weight of a polyester-modified vinyl resinhaving a hydroxyl value of 10 to 150, which is formed bygraft-polymerizing (i) 2 to 40% by weight of an unsaturated polyesterresin with 98 to 60% by weight of a monomer mixture comprising (iv) anN-alkoxymethylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid amide and (ii) at least one α,β-monoethylenicallyunsaturated monomer and (B) 85 to 5% by weight of a phosphoric acidgroup-containing copolymer resin derived from a monomer mixturecomprising (iii) an α,β-monoethylenically unsaturated monomer containinga phosphoric acid group and (ii) at least one α,β-monoethylenicallyunsaturated monomer, (C) a surface active agent and/or a thickener in anamount of 0.01 to 1.0% by weight based on said resin particles and (D) anecessary amount of water.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to an aqueous dispersion typethermosetting coating composition. More particularly, the presentinvention relates to an aqueous dispersion type thermosetting coatingcomposition having excellent properties of resulting coating and beingfree of yellowing.

The polyester-modified vinyl resin (component [IA]) that is used in thepresent invention is formed by graft-polymerizing an unsaturatedpolyester resin as the component (i) with an α,β-monoethylenicallyunsaturated monomer as the component (ii). This polyester-modified vinylresin is characterized in that a vinyl resin is imparted with the meritsof a polyester resin, such as good flexibility, good pigmentdispersibility and good coating appearance, by the graft polymerization.An α,β-unsaturated dicarboxylic acid is used as the starting compoundthat is used for formation of the above-mentioned unsaturated polyesterresin. This unsaturated dicarboxylic acid is reacted in an amount of 1to 10% by weight, preferably 3 to 7% by weight, in the unsaturatedpolyester resin.

If the amount of the unsaturated dicarboxylic acid component is smallerthan 1% by weight, this amount is insufficient for theα,β-monoethylenically unsaturated monomer at the step of forming thepolyester-modified vinyl resin, modification with the polyester resinbecomes insufficient and only a blend of the unsaturated polyester resinand a copolymer of the α,β-monoethylenically unsaturated monomer isobtained. If such polymer blend is used, blushing of the resultingcoating takes place and because of insufficient reactivity with thecross-linkable copolymer resin [IB], described hereinafter, propertiesof the resulting coating, especially adhesion, are likely to bedegraded. Therefore, it is not preferred to use the unsaturateddicarboxylic acid component in such a small amount.

On the other hand, if the amount of unsaturated dicarboxylic acidcomponent exceeds 10% by weight, gelation is caused during reaction withthe α,β-monoethylenically unsaturated monomer and good results cannot beobtained.

As the α,β-unsaturated dicarboxylic acid component, there can bementioned, for example, fumaric acid, maleic acid (maleic anhydride),itaconic acid, glutaconic acid and citraconic acid (citraconicanhydride). They may be used singly or in the form of a mixture of twoor more of them.

In the synthesis of the unsaturated polyester resin that is used in thepresent invention, a carboxylic acid component other than theabove-mentioned α,β-unsaturated dicarboxylic acid component is reactedin an amount of 29 to 69% by weight. As such carboxylic acid component,there can be mentioned, for example, phthalic acid (phthalic anhydride),isophthalic acid, trimellitic acid (trimellitic anhydride), pyromelliticacid (pyromellitic anhydride), tetrahydrophthalic acid(tetrahydrophthalic anhydride), hexahydrophthalic acid(hexahydrophthalic anhydride), methylhexahydrophthalic acid(methylhexahydrophthalic anhydride),3,6-endomethylene-tetrahydrophthalic anhydride, succinic acid (succinicanhydride), adipic acid, sebacic acid, benzoic acid andp-tert-butyl-benzoic acid. They may be used singly or in the form of amixture of two or more of them.

In the synthesis of the unsaturated polyester resin that is used in thepresent invention, a polyhydric alcohol component is reacted preferablyin an amount of 30 to 70% weight. As the polyhydric alcohol component,there can be mentioned, for example, ethylene glycol, diethylene glycol,propylene glycol, neopentyl glycol, dipropylene glycol, glycerin,trimethylolethane, trimethylolpropane, pentaerythritol,dipentaerythritol, butane diol, pentane diol, hexane diol,1,4-cyclohexane dimethanol and bisphenol A (hydrogenated bisphenol A).These polyhydric alcohols may be used singly or in the form of a mixtureof two or more of them. A glycidyl ester of a tertiary synthetic fattyacid (for example, a product manufactured and sold under trandename"Cardura E" by Shell Chemicals Co.) may be used in combination with thepolyhydric alcohol component according to need.

In addition to the above-mentioned components, there may be usedmodifiers for the unsaturated polyester resin. For example, there may beused animal and vegetable oils, their fatty acids, petroleum resins,resins, phenolic resins and epoxy resins according to need.

The unsaturated polyester resin that is used in the present invention isprepared by a one-stage or multistage reaction according to knownprocedures, and the preparation process is not particularly critical.Furthermore, a polymerization solvent such as described hereinafter maybe used as a diluent according to need.

In the unsaturated polyester resin that is used in the presentinvention, it is preferred that the acid valud be less than 50 (asdetermined with respect to the resin solid; the same will applyhereinafter), the hydroxyl value be 50 to 250 (as determined withrespect to the resin solid; the same will apply hereinafter) and theweight average molecular weight be 2,000 and 20,000.

In the instant specification, the weight average molecular weight is onedetermined according to gel permeation chromatography using achromatograph Model A801 manufactured by Tokyo Soda Co., Ltd.

In the present invention, if the acid value of the unsaturated polyesterresin (i) is more than 50, there is a degradation in properties,especially alkali resistance, of the resulting coating formed from thecoating composition comprising the polyester-modified vinyl resin [IA]formed by graft-polymerizing the unsaturated polyester with theα,β-monoethylenically unsaturated monomer. If the hydroxyl value is lessthan 50, the polyester-modified vinyl resin [IA] formed bygraft-polymerizing the unsaturated polyester with theα,β-monoethylenically unsaturated monomer is insufficient incross-linkability with the cross-linkable copolymer resin [IB] describedhereinafter. If the hydroxyl value is more than 250, the waterresistance of the resulting coating tends to decrease owing to anincrease of polar groups. If the weight average molecular weight islower than 2,000, it will not be possible for the polyester resin toexhibit its characteristics sufficiently, and if the weight averagemolecular weight exceeds 20,000, on modification with theα,β-monoethylenically unsaturated monomer, the viscosity is increasedgreatly because the molecular weight of the polyester resin is too high,and the coating workability becomes difficult.

The "polyester-modified vinyl resin" referred to in the presentinvention is one prepared by graft-polymerizing the above-mentionedunsaturated polyester resin (i) with the α,β-monoethylenicallyunsaturated monomer (ii). As the monomer (ii), there is used at leastone member selected from α,β-monoethylenically unsaturated carboxylicacids such as described hereinafter, hydroxyalkyl esters of theseα,β-monoethylenically unsaturated acids and alkyl esters of acrylic andmethacrylic acids.

The polyester-modified vinyl resin [IA] should contain in the molecule ahydroxyl group for the cross-linking reaction with the cross-linkablecopolymer resin [IB] described hereinafter. Accordingly, when thehydroxyl value of the above-mentioned unsaturated polyester resin isrelatively small, it is preferred that a hydroxyalkyl ester of anα,β-monoethylenically unsaturated carboxylic acid be used as oneα,β-monoethylenically unsaturated monomer. This hydroxyalkyl estermonomer is used in an amount of 5 to 50% by weight, preferably 8 to 30%by weight, in the α,β-monoethylenically unsaturated monomers so that thehydroxyl value of the polyester-modified vinyl resin [IA] is 30 to 200.If the hydroxyalkyl ester monomer is used in an amount of more than 50%by weight, the viscosity of the resulting polyester-modified vinyl resin[IA] becomes too high as does the cross-linkability of the resin [IA]with the cross-linkable copolymer resin [IB], with the result that theflexibility and water resistance of the resulting coating are reduced.

As the hydroxyalkyl ester monomer, there can be mentioned, for example,2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropylacrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl acrylate,3-hydroxypropyl methacrylate, 2-hydroxybutyl acrylate, 2-hydroxybutylmethacrylate, 3-hydroxybutyl acrylate, 3-hydroxybutyl methacrylate,4-hydroxybutyl acrylate, 4-hydroxybutyl methacrylate, 5-hydroxypentylacrylate, 5-hydroxypentyl methacrylate, 6-hydroxyhexyl acrylate,6-hydroxyhexyl methacrylate, neopentyl glycol monoacrylate, neopentylglycol monomethacrylate, 3-butoxy-2-hydroxypropyl acrylate,3-butoxy-2-hydroxypropyl methacrylate, 2-hydroxy-1-phenylethyl acrylate,2-hydroxy-1-phenylethyl methacrylate, polypropylene glycol monoacrylate,propylene glycol monomethacrylate, glycerin monoacrylate and glycerinmonomethacrylate. These monomers may be used singly or in the form of amixture of two or more of them.

The monomer other than the above-mentioned hydroxyalkyl ester of theα,β-monoethylenically unsaturated carboxylic acid, that is used forgraft polymerization to the unsaturated polyester resin, may be used inan amount of 50 to 95% in the monomer mixture.

As such monomer, there can be mentioned, for example,α,β-monoethylenically unsaturated carboxylic acids such as acrylic acid,methacrylic acid, itaconic acid, maleic acid and fumaric acid; alkylesters of acrylic acid and methacrylic acid such as methyl acrylate,methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-propylacrylate, p-propyl methacrylate, isopropyl acrylate, isopropylmethacrylate, n-butyl acrylate, n-butyl methacrylate, sec-butylacrylate, sec-butyl methacrylate, t-butyl acrylate, t-butylmethacrylate, isobutyl acrylate, isobutyl methacrylate, n-hexylacrylate, n-hexyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexylmethacrylate, n-octyl acrylate, n-octyl methacrylate, lauryl acrylate,lauryl methacrylate, tridecyl acrylate, tridecyl methacrylate, stearylacrylate and stearyl methacrylate; N,N'-dimethylaminoethyl acrylate,N,N'-dimethylaminoethyl methacrylate, glycidyl acrylate, glycidylmethacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, phenylmethacrylate, benzyl methacrylate, dialkyl esters of fumaric acid suchas dimethyl fumarate, styrene, vinyl toluene, α-methyl styrene,acrylonitrile, methacrylonitrile and vinyl acetate. These monomers areappropriately chosen according to the intended object and use of thefinal coating composition, and they may be used singly or in the form ofa mixture of two or more of them.

In the first embodiment [I] of the present invention, thepolyester-modified vinyl resin [IA] is composed of a graftpolymerization product of 5 to 50% by weight of the above-mentionedunsaturated polyester resin (i) and 50 to 95% by weight of at least oneα,β-monoethylenically unsaturated monomer (ii) such as mentioned above.As pointed out hereinbefore, the modification quantity of theunsaturated polyester resin is 5 to 50% by weight and preferably 10 to40% by weight. If the modification quantity is less than 5% by weight,excellent properties of the polyester resin, such as good flexibility,good pigment dispersibility and good coating appearance are notsufficiently exhibited, and if the modification quantity is more than50% by weight, good characteristics of the vinyl resin, such as highhardness and good stain resistance, are degraded. Accordingly, in eachcase, good results cannot be obtained.

In the second embodiment [II] of the present invention, a phosphoricacid group-containing α,β-monoethylenically unsaturated monomer as thecomponent (iii) is introduced into the polyester-modified vinyl resin[IIA].

As the monomer (iii), there can be mentioned, for example, hydroxylgroup-containing primary phosphoric acid esters of acrylic acid andmethacrylic acid such as acid phosphoxyethyl acrylate, acidphosphoxyethyl methacrylate, acid phosphoxypropyl acrylate, acidphosphoxypropyl methacrylate and 3-chloro-2-acid-phosphoxypropylmethacrylate, and bisacryloxyethyl phosphate, bismethacryloxyethylphosphate, acryl alcohol acid phosphate, vinyl phosphate,mono[2-hydroxyethyl acrylate] acid phosphite, mono[2-hydroxyethylmethacrylate] acid phosphite and salts and esters thereof. Thesemonomers may be used singly or in the form of a mixture of two or moreof them. These monomers may be prepared by reacting a hydroxylgroup-containing α,β-monoethylenically unsaturated monomer withphosphoric anhydride and hydrolyzing the resulting reaction product.Furthermore, they may be prepared by using orthophosphoric acid,meta-phosphoric acid, phosphorus oxychloride, phosphorus trichloride orphosphorus pentachloride.

In the embodiment [II] using the phosphoric acid group-containingα,β-monoethylenically unsaturated monomer (iii), as pointed outhereinbefore, the component (i) is used in an amount of 2 to 50% byweight and the component (ii) is used in an amount of 95 to 40% byweight, and the component (iii) is used in an amount of 0.01 to 10.0%weight, preferably 0.5 to 6.0% by weight.

If the amount of the component (iii) is less than 0.01% by weight,attainment of the intended effects of the present invention, that is,the flash rusting-preventing effect, the effect of improving the storagestability and the effect of enhancing the corrosion resistance, cannotbe expected, and if the amount of the component (iii) exceeds 10% byweight, gelation is readily caused during the graft polymerizationprocess, and since satisfactory results are obtained with use of up to10% by weight of the component (iii), also from the economicalviewpoint, it is not preferred to use the component (iii) in an amountexceeding 10% by weight.

As pointed out hereinbefore, the modification quantity of theunsaturated polyester resin is 2 to 50% by weight and preferably 10 to40% by weight. If the modification quantity of the unsaturated polyesterresin is less than 2% by weight, excellent properties of the polyesterresin such as high flexibility, good pigment dispersibility and goodcoating appearance cannot be sufficiently exhibited, and if themodification quantity of the unsaturated polyester resin exceeds 50% byweight, characteristics of the vinyl resin such as high hardness andgood stain resistance are degraded.

The polyester-modified vinyl resin [IIA] should contain in the moleculea hydroxyl group for cross-linking reaction with the cross-linkablecopolymer resin [IIB] described hereinafter. Accordingly, when thehydroxyl value of the unsaturated polyester resin is relatively small,it is preferred that a hydroxyalkyl ester of an α,β-monoethylenicallyunsaturated carboxylic acid be used as one α,β-monoethylenicallyunsaturated monomer. The hydroxyalkyl ester monomer is used in an amountof 1 to 40% by weight, preferably 5 to 20% by weight, in theα,β-monoethylenically unsaturated monomers so that the hydroxyl value ofthe polyester-modified vinyl resin is 30 to 200. When this monomer isused in an amount exceeding 40% by weight, the viscosity of theresulting polyester-modified vinyl resin [IIA] becomes too high as doesthe density of cross-linking with the cross-linking copolymer resin[IIB] described hereinafter, resulting in reduction of flexibility andwater resistance of the resulting coating.

Monomers mentioned hereinbefore with respect to the synthesis of thepolyester-modified vinyl resin may also be used as the hydroxyalkylester in the second embodiment for the synthesis of thepolyester-modified vinyl resin [IIA].

The monomer other than the phosphoric acid group-containingα,β-monoethylenically unsaturated monomer and the hydroxyalkyl ester ofthe α,β-monoethylenically unsaturated carboxylic acid, that is used forgraft polymerization to the unsaturated polyester resin, may be used inan amount of 60 to 99% by weight, preferably 80 to 95% by weight, in themonomer mixture.

Monomers mentioned above with respect to the synthesis of thepolyester-modified vinyl resin [IA] may also be used as such monomer forthe synthesis of the polyester-modified vinyl resin [IIA].

By introducing the above-mentioned phosphoric acid group-containingα,β-monoethylenically unsaturated monomer into the polyester-modifiedvinyl resin [IIA], even if the resulting coating composition is directlycoated on an iron plate, occurrence of flash rusting is inhibited, andthe storage stability of the coating composition is remarkably improved.Furthermore, the adhesion of the coating to the metal surface is furtherenhanced and very excellent corrosion resistance and water resistancecan be obtained.

The polyester-modified vinyl resin [IA] or [IIA] may be preparedaccording to the customary solution polymerization process. For example,there may be adopted a method in which a mixture of the unsaturatedpolyester resin and some monomer (or a part of the monomer mixture) in apolymerization solvent is prepared and the remaining monomer (or theremaining monomer mixture) and a polymerization initiator are addeddropwise to the mixture to effect polymerization, and a method in whichthe unsaturated polyester resin, monomers (or the monomer mixture) and apolymerization initiator are added dropwise to a polymerization solventto effect polymerization. However, the solution polymerization method isnot particularly critical in the present invention.

The polymerization temperature is ordinarily between about 50° C. andabout 150° C., and the polymerization time is usually within a range ofabout 4 to about 12 hours, though the polymerization time is changed tosome extent depending on the polymerization temperature.

A water-soluble or water-miscible solvent is used as the polymerizationsolvent in the above-mentioned solution polymerization process. Forexample, there may be employed alcohols such as methyl alcohol, ethylalcohol, isopropyl alcohol and n-propyl alcohol; ethylene glycolderivatives such as ethylene glycol monomethyl ether, ethylene glycolmonoethyl ether, ethylene glycol monobutyl ether and ethylene glycolmonoethyl ether acetate; diethylene glycol derivatives such asdiethylene glycol monomethyl ether, diethylene glycol monoethyl etherand diethylene glycol monobutyl ether; esters such as methyl acetate,ethyl acetate and butyl acetate; and ketones such as methylethyl ketoneand methylisobutyl ketone. These polymerization solvents may be usedsingly or in the form of a mixture of two or more of them. Apolymerization solvent having a water solubility of about 10 to about30% by weight as determined at 20° C. is especially preferred.

For the synthesis of the polyester-modified vinyl resin [IA], thepolymerization solvent is preferably used in such an amount that thenon-volatile component content of the resin is 10 to 80% by weight,particularly 35 to 75% by weight, and for the synthesis of thepolyester-modified vinyl resin [IIA], the polymerization solvent ispreferably used in such an amount that the non-volatile componentcontent of the resin is 10 to 80% by weight, particularly 20 to 70% byweight. In the second embodiment [II], it is preferred that thenon-volatile component content be reduced with an increase in the amountused of the phosphoric acid group-containing α,β-monoethylenicallyunsaturated monomer.

As the polymerization initiator that is used for the solutionpolymerization, there can be mentioned, for example, organic peroxidessuch as benzoyl peroxide, t-butyl perbenzoate, t-butyl hydroperoxide,cumene hydroperoxide, di-t-butyl peroxide and t-butyl peroctoate, andazo compounds such as azobisisobutyronitrile and azodiisobutyronitrile.These polymerization initiators may be used singly or in the form of amixture of two or more of them. The polymerization initiator is used inan amount of about 0.1 to about 15% by weight based on the non-volatilecomponents for the synthesis of the polyester-modified vinyl resin.

Furthermore, a chain transfer agent for adjusting the molecular weight,such as dodecylmercaptan, 2-ethylhexyl thioglycolate or carbontetrachloride, may be used according to need. The chain transfer agentis used in an amount up to about 5% by weight based on the non-volatilecomponents for the synthesis of the polyester-modified vinyl resin.

The polyester-modified vinyl resin [IA] or [IIA] that is used in thepresent invention has a hydroxyl value of 30 to 200, preferably 50 to150, and an acid value of 5 to 30, preferably 7 to 27. If the acid valueis less than 5, since the thermosettability is insufficient, theresulting coating is poor in hardness, water resistance, corrosionresistance and durability. On the other hand, if the acid value exceeds30, the properties of the coating and the storage stability of thecoating composition are degraded. If the hydroxyl value is less than 30,the cross-linking density is lowered, and the solvent resistance of theresulting coating is degraded. On the other hand, if the hydroxyl valueexceeds 200, both the flexibility and water resistance of the resultingcoating are degraded.

It is preferred that the weight average molecular weight of thepolyester-modified vinyl resin [IA] that is used in the presentinvention be 10,000 to 80,000, especially 20,000 to 60,000. When theweight average molecular weight is lower than 10,000, the properties ofthe resulting coating are insufficient, and if the weight averagemolecular weight exceeds 80,000, the smoothness is lost in the resultingcoating and good results cannot be obtained.

It is preferred that the weight average molecular weight of thepolyester-modified vinyl resin [IIA] be 20,000 100,000, especially30,000 to 80,000. If the weight average molecular weight is lower than20,000, the properties of the coating are insufficient, and if theweight average molecular weight exceeds 100,000, the smoothness is lostin the resulting coating and good results are not obtained.

Since the polyester-modified vinyl resin [IIA] that is used in thepresent invention is high in reactivity, the viscosity tends to increasewhen the temperature is high, for example, in summer. In this case, forfurther improving the storage stability, the acid group introduced inthe polyester-modified vinyl resin is neutralized by a basic compound,whereby the polyester-modified vinyl resin is rendered more stable. Asthe basic compound, there can be mentioned, for example, alkali metalhydroxides such as sodium hydroxide and potassium hydroxide,water-soluble amines such as ammonia, monomethylamine, dimethylamine,trimethylamine, triethylamine, monoethylamine, mono-n-propylamine anddimethyl-n-propylamine, and water-soluble hydroxylamines such asmonoethanol amine, diethanol amine, triethanol amine, N-methylethanolamine, N-aminoethylethanol amine, N-methyldiethanol amine,monoisopropanol amine, diisopropanol amine, tripropanol amine andhydroxylamine. These basic compounds may be used singly or in the formof a mixture of two or more of them. In the present invention, thisneutralization with the basic compound includes neutralization of a partof the acid group contained in the polyester-modified vinyl resin [IIA]and neutralization of all of the acid group contained in thepolyester-modified vinyl resin [IIA]. Furthermore, in view of thestability of the polyester-modified vinyl resin [IIA] or properties ofthe resulting coating, the basic compound may be added in an excessamount.

In the present invention, an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide is used as theindispensable component (iv). This component (iv) is indispensable forcross-linking of the cross-linkable copolymer resin [IB] or [IIB] withthe above-mentioned polyester-modified vinyl resin [IA] or [IIA]. Thecomponent (iv) is reacted in an amount of 5 to 30% by weight, preferably10 to 25% by weight, in the cross-linkable copolymer resin [IB] or[IIB]. If the amount of the component (iv) is less than 5% by weight,the cross-linking reaction with the polyester-modified vinyl resin isinsufficient and the solvent resistance of the resulting coating isdegraded, and if the amount of the component (iv) is more than 30% byweight, gelation is caused during preparation of the cross-linkablecopolymer resin and good results cannot be obtained.

As the component (iv), there can be mentioned, for example,N-alkoxymethylated products of α,β-monoethylenically unsaturatedcarboxylic acid amides such as N-methoxymethyl acrylamide,N-methoxymethyl methacrylamide, N-ethoxymethyl acrylamide,N-ethoxymethyl methacrylamide, N-n-propoxymethyl acrylamide,N-n-propoxymethyl methacrylamide, N-isopropoxymethyl acrylamide,N-isopropoxymethyl methacrylamide, N-n-butoxymethyl acrylamide,N-n-butoxymethyl methacrylamide, N-sec-butoxymethyl acrylamide,N-sec-butoxymethyl methacrylamide, N-t-butoxymethyl acrylamide,N-t-butoxymethyl methacrylamide, N-isobutoxymethyl acrylamide andN-isobutoxymethyl methacrylamide, and N-methylolated products thereof.These compounds may be used singly or in the form of a mixture of two ormore.

In the present invention, an α,β-monoethylenically unsaturatedcarboxylic acid may be used in an amount of 0.5 to 10% by weight as onecomponent of the cross-linkable copolymer resin [IB] or [IIB]. Thismonomer has effects of improving the compatibility of the cross-linkablecopolymer resin with the polyester-modified vinyl resin and promotingthe cross-linking reaction between them. If the amount of this monomeris less than 0.5% by weight, these effects are low, and if the amount ofthis monomer is more than 10% by weight, properties of the curedcoatings are degraded and good results cannot be obtained.

As specific examples of the above-mentioned monomer, there can bementioned acrylic acid, methacrylic acid, crotonic acid, itaconic acid,maleic acid and fumaric acid. These compounds may be used singly or inthe form a mixture of two or more of them.

For the synthesis of the cross-linkable copolymer resin [IB] or [IIB], acopolymerizable α,β-ethylenically unsaturated monomer other thanmentioned above is preferably reacted in an amount of 60 to 90% byweight. As such copolymerizable monomer, there can be mentioned, forexample, alkyl esters of acrylic acid and methacrylic acid such asmethyl acrylate, methyl methacrylate, ethyl acrylate, ethylmethacrylate, n-propyl acrylate, n-propyl methacrylate, isopropylacrylate, isopropyl methacrylate, n-butyl acrylate, n-butylmethacrylate, sec-butyl acrylate, sec-butyl methacrylate, t-butylacrylate, t-butyl methacrylate, isobutyl acrylate, isobutylmethacrylate, n-hexyl acrylate, n-hexyl methacrylate, 2-ethylhexylacrylate, 2-ethylhexyl methacrylate, n-octyl acrylate, n-octylmethacrylate, lauryl acrylate, lauryl methacrylate, tridecyl acrylate,tridecyl methacrylate, stearyl acrylate and stearyl methacrylate;hydroxyalkyl esters of α,β-ethylenically unsaturated carboxylic acidssuch as 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate,2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropylacrylate, 3-hydroxypropyl methacrylate, 2-hydroxybutyl acrylate,2-hydroxybutyl methacrylate, 3-hydroxybutyl acrylate, 3-hydroxybutylmethacrylate, 4-hydroxybutyl acrylate, 4-hydroxybutyl methacrylate,5-hydroxypentyl acrylate, 5-hydroxypentyl methacrylate, 6-hydroxyhexylacrylate, 6-hydroxyhexyl methacrylate, neopentyl glycol monoacrylate,neopentyl glycol monomethacrylate, 3-butoxy-2-hydroxypropyl acrylate,5-butoxy-2-hydroxypropyl methacrylate, 2-hydroxy-1-phenylethyl acrylate,2-hydroxy-1-phenylethyl methacrylate, polypropylene glycol monoacrylate,propylene glycol monomethacrylate, glycerin monoacrylate and glycerinmonomethacrylate; and other monomers such as N'-dimethylaminoethylacrylate, N'-dimethylaminoethyl methacrylate, glycidyl acrylate,glycidyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate,phenyl methacrylate, benzyl methacrylate, alkyl esters of fumaric acid,e.g., dibutyl fumarate, styrene, vinyl toluene, α-methylstyrene,acrylonitrile, methacrylonitrile and vinyl acetate. These monomers maybe chosen appropriately according to the intended object and use of theresulting coating composition and used singly or in the form of amixture of two or more of them.

The cross-linkable copolymer resin [IB] or [IIB] may be prepared by thesolution polymerization according to customary procedures. Awater-soluble or water-miscible solvent such as mentioned above may beused for the solution polymerization, and an organic peroxide or azocompound such as mentioned above may be used as the polymerizationinitiator. Furthermore, a chain transfer agent such as mentioned abovemay be used for adjusting the molecular weight. The polymerization forthe synthesis of the cross-linkable copolymer resin is carried out at atemperature of about 50° to about 150° C. for about 4 to about 12 hours.The amount of the polymerization solvent is adjusted so that theconcentration of the non-volatile components for the synthesis of thecopolymer resin is 10 to 80% by weight, preferably 35 to 75% by weight.The amount of the polymerization initiator used is about 0.1 to about15% by weight based on the non-volatile components for the synthesis ofthe cross-linkable copolymer resin, and the chain transfer agent is usedin an amount of up to about 5% by weight based on the non-volatilecomponents for the synthesis of the cross-linkable copolymer resin.

In the first embodiment [I], it is preferred that the weight averagemolecular weight of the cross-linkable copolymer resin be 10,000 to70,000, especially 20,000 to 60,000. If the weight average molecularweight is lower than 10,000, the properties of the resulting coating areinsufficient, and if the weight average molecular weight is higher than70,000 the smoothness of the resulting coating is degraded.

In the second embodiment [II], it is preferred that the weight averagemolecular weight of the cross-linkable copolymer resin be 10,000 to100,000, especially 20,000 to 80,000.

In the present invention, (A) the above-mentioned polyester-modifiedvinyl resin [IA] or [IIA] is mixed with (B) the above-mentionedcross-linkable copolymer resin [IB] or [IIB]. The mixing weight ratio ofthe polyester-modified vinyl resin to the cross-linkable copolymer resinis in the range of from 5/95 to 90/10, preferably from 10/90 to 70/30.If the amount of the cross-linkable copolymer resin is less than 10% byweight, the cross-linking density is low in the resulting coating andthe solvent resistance and chemical resistance of the coating tend todecrease. On the other hand, if the amount of the cross-linkablecopolymer resin is more than 95% by weight, the amount of thepolyester-modified vinyl resin is reduced and excellent characteristicsinherent of the polyester resin, such as excellent flexibility, goodpigment dispersibility and good coating appearance, cannot bemanifested, with the result that the intended objects of the presentinvention cannot be attained.

In the present invention, it is preferred that particles composed of thepolyester-modified vinyl resin [IA] or [IIA] and the cross-linkablecopolymer resin [IB] or [IIB] should have a softening point of 30° to100° C., especially 40° to 80° C. If the softening point is lower than30° C., the storage stability of the coating composition becomes poor,and if the softening point is higher than 100° C., properties of thecoating, for example, the surface smoothness, are degraded.

In the present invention, a known acid catalyst may be used forpromoting the cross-linking reaction between the polyester-modifiedvinyl resin and the cross-linkable copolymer resin. Furthermore, afilm-forming resin such as an epoxy resin, a cellulose type resin or anamino resin may be used in combination with the foregoing resincomponents.

The third embodiment [III] of the present invention will now bedescribed. In this embodiment, a monomer mixture containing (iv) anN-alkoxy-methylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid amide is used for the synthesis of thepolyester-modified vinyl resin, and a phosphoric acid group-containingcopolymer resin derived from a monomer mixture containing (iii) anα,β-monoethylenically unsaturated monomer containing a phosphoric acidgroup is used as the cross-linkable copolymer resin (B).

In this third embodiment [III] of the present invention, thepolyester-modified vinyl resin to be used is prepared bygraft-copolymerizing an unsaturated polyester resin such as mentionedabove with a monomer mixture containing at least (iv) anN-alkoxymethylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid amide and another ordinary α,β-monoethylenicallyunsaturated carboxylic acid amide and another ordinaryα,β-monoethylenically unsaturated monomer, for example, anα,β-monoethylenically unsaturated carboxylic acid describedhereinbefore, a hydroxyalkyl ester thereof, or an alkyl ester of acrylicacid or methacrylic acid.

In this embodiment [III], the polyester-modified vinyl resin [IIIA]should contain in the molecule a hydroxyl group for not onlycross-linking with the phosphoric acid group-containing copolymer resin[IIB] but also for a self-cross-linking reaction.

Accordingly, when the hydroxyl value of the unsaturated polyester resinis relatively small, it is preferred that a hydroxyalkyl ester of anα,β-monoethylenically unsaturated carboxylic acid be used as oneα,β-monoethylenically unsaturated monomer.

The hydroxylalkyl ester monomer is used in an amount of 1 to 30% byweight, preferably 3 to 20% by weight, in the starting monomer mixtureso that the hydroxyl value of the polyester-modified vinyl resin is 10to 150.

When the hydroxyalkyl ester monomer is used in an amount exceeding 30%by weight, the polyester-modified vinyl resin [IIIA] is highly viscousand the cross-linking degree of the product formed by the thermosettingreaction with the phosphoric acid group-containing copolymer resin[IIIB] becomes too high. Therefore, such properties of the resultingcoating as flexibility and water resistant tend to decrease and goodresults are not obtained.

The hydroxyalkyl ester monomers mentioned above with respect to thesynthesis of the polyester-modified vinyl resins [IA] and [IIA] aresimilarly used also in this embodiment [III].

The N-alkoxymethylated monomer of the polymerizableα,β-monoethylenically unsaturated carboxylic acid amide that is used forthe graft polymerization with the unsaturated polyester resin isindispensible for the cross-linking reaction with the hydroxyalkyl esterof the α,β-monoethylenically unsaturated carboxylic acid and thepolyester resin component. As this monomer component, those mentionedabove for the synthesis of the polyester-modified vinyl resin [IA] or[IIA] may be used. This monomer component is graft-polymerized in anamount of 5 to 30% by weight, preferably 10 to 20% by weight, in theα,β-monoethylenically unsaturated monomer mixture. If the amount of thismonomer component is less than 5% by weight, the cross-linkingreactivity of the polyester-modified vinyl resin [IIIA] is insufficientand the solvent resistance of the resulting coating is reduced. When theamount of this monomer component exceeds 30% by weight, gelatin iscaused during the graft polymerization and good results are notobtained.

In the third embodiment [III] of the present invention, an α,β-monoethylenically unsaturated monomer other than the hydroxyalkylester of the α,β-monoethylenically unsaturated carboxylic acid and theN-alkoxymethylated monomer of the α,β-monoethylenically unsaturatedcarboxylic acid amide may be used in combination with these monomers. Assuch α,β-monoethylenically unsaturated monomer, there may be used thosementioned above for the synthesis of the polyester-modified vinyl resin[IA], and such α, β-monoethylenically unsaturated monomer is preferablyused in an amount of 60 to 90% by weight in the starting monomermixture.

In the embodiment [III], the polyester-modified vinyl resin [IIIA] isformed by graft-polymerizing 2 to 40% by weight of the above-mentionedunsaturated polyester resin with 60 to 98% by weight of theabove-mentioned monomer mixture. The modification quantity of theunsaturated polyester resin is 2 to 40% by weight, preferably 5 to 30%by weight. If the modification quantity is smaller than 2% by weight,the excellent properties of the polyester resin, such as goodflexibility, good pigment dispersibility and excellent coatingappearance are not sufficiently exhibited, and if the modificationquantity of the polyester resin exceeds 40% by weight, goodcharacteristics of the vinyl resin such as high hardness and good stainresistance are degraded.

The polyester-modified vinyl resin [IIIA] is prepared by the solutionpolymerization in the same manner as described hereinbefore with respectto the polyester-modified vinyl resin [IA].

The hydroxyl value of this polyester-modified vinyl resin [IIIA] is 10to 150, preferably 20 to 100, and the acid value thereof is 3 to 40,preferably 5 to 25. If the acid value is less than 3, the thermosettingproperty becomes insufficient and the resulting coating is poor inhardness, water resistance, corrosion resistance and durability. On theother hand, if the acid value exceeds 40, the properties of the coatingand the storage stability of the coating composition are degraded. Ifthe hydroxyl value is smaller than 10, the cross-linking density isreduced and the solvent resistance of the resulting coating is degraded.On the other hand, if the hydroxyl value is larger than 150, both theflexibility and the water resistance of the resulting coating are poor.

In the third embodiment [III] of the present invention, is is preferredthat the weight average molecular weight of the polyester-modified vinylresin [IIIA] be 40,000 to 200,000, especially 50,000 to 150,000. If theweight average molecular weight is lower than 40,000, the properties ofthe coating are insufficient, and if the weight average molecular weightexceeds 200,000, the smoothness of the coating is degraded and goodresults are not obtained.

The phosphoric acid group-containing copolymer resin [IIIB] that is usedin the embodiment [III] is formed by copolymerizing the phosphoric acidgroup-containing α,β-monoethylenically unsaturated monomer as theindispensable component with other α,β-monoethylenically unsaturatedmonomer. By introducing the phosphoric acid group-containingα,β-monoethylenically unsaturated monomer into the copolymer resin[IIIB], even when the resulting coating composition is directly coatedon an iron plate, flash rusting is controlled and the adhesion to themetal surface is highly improved. Moreover, the storage stability of thecoating composition is improved, and there can be obtained a coatingexcellent in such properties as corrosion resistance and waterresistance.

The above-mentioned phosphoric acid group-containingα,β-monoethylenically unsaturated monomer is used in an amount of 0.01to 10.0% by weight, preferably 0.5 to 5.0% by weight, in the monomermixture. When the amount of this monomer is less than 0.1% by weight,the intended effects of the present invention, that is, the effects ofpreventing flash rusting, improving storage stability and enhancingcorrosion resistance, cannot be attained. If the amount of this monomerexceeds 10% by weight, gelation is caused during the polymerizationprocess and good results can not be obtained. Furthermore, sincesatisfactory results are obtained even if this monomer is used in anamount of up to 10% by weight, from the economical viewpoint, it is notpreferred to use this monomer in an amount exceeding 10% by weight.

As the phosphoric acid group-containing α,β-monoethylenically monomer,there can be used those mentioned hereinbefore with respect to thesynthesis of the polyester-modified vinyl resin [IIA].

As the α,β-monoethylenically unsaturated monomer other than thephosphoric acid group-containing α,β-monoethylenically unsaturatedmonomer as the indispensable component, that is used in combination withthis indispensable monomer for the synthesis of the phosphoric acidgroup-containing copolymer resin [IIIB], there can be used ordinaryα,β-monoethylenically unsaturated monomers, for example,α,β-monoethylenically unsaturated carboxylic acids such as mentionedabove, hydroxyalkyl esters thereof and alkyl esters of acrylic acid andmethacrylic acid. These monomers may be used singly or in the form of amixture of two or more of them.

The phosphoric acid group-containing copolymer resin [IIIB] shouldcontain in the molecule a hydroxyl group for cross-linking with thepolyester-modified vinyl resin [IIIA]. Accordingly, in order to attain agood balance between the components [IIIA] and [IIIB] with respect tothe contained hydroxyl groups, it is preferred that an appropriateamount of a hydroxyalkyl ester of an α,β-monoethylenically unsaturatedcarboxylic acid be used as one α,β-monomethylenically unsaturatedmonomer for the synthesis of the phosphoric acid group-containingcopolymer resin [IIIB].

The hydroxyalkyl ester monomer is used in an amount of 1 to 30% byweight, preferably 2 to 15% by weight, in the starting monomer mixtureto be used for the synthesis of the phosphoric acid group-containingcopolymer resin [IIIB]. If this monomer is used in an amount exceeding30% by weight, gelation is readily caused during the copolymerizationreaction, and the resulting phosphoric acid group-containing copolymerresin [IIIB] becomes highly viscous and the density of crosslinking withthe polyester-modified vinyl resin [IIIA] becomes too high, resulting inreduction of flexibility and water resistance of the resulting coating.Accordingly, it is not preferred to use the hydroxyalkyl ester monomerin such a large amount. As the hydroxyalkyl ester monomer, use can bemade of those described hereinbefore.

In the third embodiment [III] of the present invention it is preferredthat an α,β-monoethylenically unsaturated carboxylic acid be used in anamount of 0.5 to 10% by weight as one component of the phosphoric acidgroup-containing copolymer resin [IIIB]. This monomer improves thecompatibility of the phosphoric acid group-containing copolymer resin[IIIB] with the polyester-modified vinyl resin [IIIA] and thecross-linking reaction between them is promoted. When the amount of thismonomer is less than 0.5% by weight, these effects are not prominent,and if the amount of this monomer exceeds 10% by weight, the propertiesof the resulting cured coating are degraded and good results are notobtained.

As such monomer, there can be mentioned, for example, acrylic acid,methacrylic acid, crotonic acid, itaconic acid maleic acid and fumaricacid. These compounds may be used singly or in the form of a mixture oftwo or more of them.

In the third embodiment [III] of the present invention, it is preferredthat a copolymerizable α,β-monoethylenically unsaturated monomer, otherthan the monomers mentioned above, be used in an amount of 70 to 90% byweight as one starting monomer for the synthesis of the phosphoric acidgroup-containing copolymer resin [IIIB]. As such monomer, there can beused copolymerizable α,β-monoethylenically unsaturated monomersmentioned hereinbefore with respect to the synthesis of thecross-linkable copolymer resin [IB] or [IIB].

The phosphoric acid group-containing copolymer resin [IIIB] used in theembodiment [III] of the present invention is prepared by the solutionpolymerization according to customary procedures. A water-soluble orwater-miscible solvent such as mentioned above is used as the solventfor the solution polymerization. An organic peroxide or azo compoundsuch as mentioned above is used as the polymerization initiator.Furthermore, a chain transfer agent such as mentioned above may be usedso as to adjust the molecular weight. The polymerization reaction forthe synthesis of the phosphoric acid group-containing copolymer resin[IIIB] is ordinarily carried out at a temperature of about 50° to about150° C. for about 4 to about 12 hours. It is preferred that the solventbe used in such an amount that the non-volatile component content in thereaction mixture for the synthesis of the copolymer resin [IIIB] is 10to 80% by weight, especially 20 to 70% by weight. It is especiallypreferred that the non-volatile component content be reduced with anincrease in the amount used of the phosphoric acid group-containingα,β-monoethylenically monomer. Furthermore, it is preferred that thepolymerization initiator and chain transfer agent be used in amounts ofabout 0.1 to about 15% by weight and up to about 5% by weight,respectively, based on the non-volatile components for the synthesis ofthe copolymer resin [IIIB].

In the third embodiment [III] of the present invention, it is preferredthat the weight average molecular molecular weight of the phosphoricacid group-containing copolymer resin [IIIB] be 8,000 to 70,000,especially 20,000 to 50,000. If the weight average molecular weight islower than 8,000, the properties of the resulting coating areinsufficient, and if the weight average molecular weight exceeds 70,000,the smoothness of the resulting coating is degraded.

It is preferred that the hydroxyl value of the phosphoric acidgroup-containing copolymer resin [IIIB] be in the range of 3 to 150.

Since the phosphoric acid group-containing copolymer resin [IIIB] ishigh in reactivity, the viscosity is readily increased when thetemperature is high, for example, in summer. In this case, in order tofurther improve the storage stability, a basic compound is incorporatedfor neutralizing the acid groups introduced into the phosphoric acidgroup-containing copolymer resin, whereby the phosphoric acidgroup-containing copolymer resin [IIIB] is rendered more stable.

As such basic compound, there can be used those mentioned above withrespect to neutralization of the acid groups contained in thepolyester-modified vinyl resin [IIA].

Neutralization with such basic compound includes not only neutralizationof a part of the phosphoric acid group contained in the copolymer resin[IIIB] but also neutralization of all of the phosphoric acid groupcontained in the copolymer resin [IIIB]. Furthermore, in view of thestability of the resulting coating composition or the properties of thecoating, the basic compound may be added to an excess amount.

In the third embodiment [III] of the present invention, thepolyester-modified vinyl resin [IIIA] and the phosphoric acidgroup-containing copolymer resin [IIIB] is used at a [IIIA]/[IIIB]weight ratio of from 15/85 to 95/5, preferably from 30/70 to 90/10.

If the amount of the polyester-modified vinyl resin [IIIA] is less than15% by weight, the excellent properties of the polyester resin, such asgood flexibility, good pigment dispersibility and good coatingappearance, are not sufficiently exhibited. On the other hand, if theamount of the polyester-modified vinyl resin [IIIA] exceeds 95% byweight, the amount of the phosphoric acid group-containing copolymerresin [IIIB] is inevitably reduced, and the intended effect of thepresent invention, that is, the effect of preventing flash rusting, ishardly attained in addition, the corrosion resistance and waterresistance are degraded.

It is preferred that the softening point of the resin particles composedof the polyester-modified vinyl resin [IIIA] and the phosphoric acidgroup-containing copolymer resin [IIIB], that are used in the thirdembodiment [III] of the present invention, be 30° to 100° C., especially40° to 80° C. If the softening point of the resin particles is lowerthan 30° C., the storage stability of the coating composition tends todecrease, and if the softening point is higher than 100° C., thesmoothness of the coating is degraded and good results cannot beobtained.

In the third embodiment [III] of the present invention, a known acidcatalyst may be added to promote the cross-linking reaction between thepolyester-modified vinyl resin [IIIA] and the phosphoric acidgroup-containing copolymer resin [IIIB], and furthermore, a film-formingresin such as an epoxy resin,, a cellulose type resin or an amino resinmay be used in combination with the above resin components [IIIA] and[IIIB] according to need.

The process for the preparation of the aqueous dispersion typethermosetting coating composition of the present invention will now bedescribed. A customary mechanical pulverization method adopted forpreparation of conventional powdery paints and slurry paints may beused, but when the softening point of the starting resin composition islow, powdering is difficult according to this mechanical pulverizationmethod because the stickiness of the resin composition is too high. Thefollowing special process, therefore, is advantageously adopted for thepreparation of the aqueous dispersion type thermosetting coatingcomposition of the present invention.

At first, predetermined amounts of the polyester-modified vinyl resin[IA], [IIA] or [IIIA] and the cross-linkable copolymer resin [IB], [IIB]or [IIIB] are dissolved, optionally together with a basic compound in anamount sufficient to neutralize a part of all of the acid groups,contained in the polyester-modified vinyl resin [IIA] or phosphoric acidgroup-containing copolymer resin [IIIB], a curing catalyst and otherfilm-forming resin, into a water-soluble or water-miscible solvent suchas mentioned above to form a resin solution. If desired, a pigment isincorporated in the solution and kneaded therewith to form a pigmentdispersion.

As the solvent, there are employed those mentioned above with respect tothe solution polymerization, and the amount of the solvent is adjustedso that the non-volatile component content in the solution or dispersionis 30 to 80% by weight.

Then, the so formed resin solution or pigment dispersion is dispersed inthe fine particulate state into water in an amount sufficient todissolve all of the water-soluble or water-miscible solvent contained inthe resin solution or pigment dispersion. More specifically, the amountof water is at least 6 times the amount of the resin solution or pigmentdispersion based on the weight, and in view of the facility of thesubsequent step of filtering the resulting composition, it is preferredthat the amount of water be up to about 40 times the amount of the resinsolution or pigment dispersion based on the weight.

The dispersion of the resin solution or pigment dispersion may beaccomplished according to a method in which the solution or pigmentdispersion is dropped and poured into water being violently agitated ora method in which the solution or pigment dispersion is mixed with waterby means of a line mixer. When the temperature of the liquid mixture iselevated by agitation and the resin particles are aggregated orintegrated by softening of the resins, in order to prevent formation ofcoarse particles, it is preferred that the liquid mixture be cooled andthe temperature be maintained below 30° C.

The above mentioned agitation or mixing by the line mixer is conducteduntil the solvent in the emulsified fine particles is transferred intowater and resin particles are formed. Thus, the solvent contained in thedispersed fine particles is extracted into water to obtain the intendedresin particles.

The so formed resin particles are separated from the water-solventmixture by filtration or centrifugal separation, and if necessary, waterwashing and separation are repeated several times to obtain the resinparticles in the form of a slurry or water-containing cake. Thus, resinparticles having preferably an average particle size of about 1 to about200 μ are obtained. Each of the so obtained resin particles includesboth the polyester-modified vinyl resin and the cross-linkable copolymerresin. In other words, respective resin particles contain groups to bereacted with each other under heating, that is, hydroxyl and amidegroups. Therefore, when the coating composition of the present inventionis heated, a cross-linking reaction is caused both in the respectiveresin particles and among the resin particles, and a coating havingexcellent properties can be formed.

Then, a surface active agent and/or a thickener and water are added tothe resin particles in the form of a slurry or water-containing cake,and the resin particles are finely pulverized by using a dispersingmachine customarily used for the preparation of paints, such as a sandmill, a ball mill, a disperser, a Sussmeyer mill or a Centri mill sothat the average particle size is adjusted to about 1 to about 50μ.

It is preferred that the aqueous dispersion type thermosetting coatingcomposition of the present invention contain the above-mentioned resinparticles in the form of fine dispersed particles having an averageparticle size 1 to 50μ. When the average particle size is smaller than1μ, the tendency of the particles to agglomerate is increased andpopping is readily caused at the film-forming heating step. In short, inthis case, properties of the coating composition resemble those of awater-soluble paint and good results cannot be obtained. When theaverage particle size exceeds 50μ, sedimentation or cohesion of theresin particles is readily caused during storage, and a coating having asmooth surface is hardly obtained. Accordingly, such a large particlesize is not preferred. When resin particles having an average particlesize of 5 to 30μ are used, the resulting coating composition isexcellent in storage stability and provides a smooth coating free ofbubbling, and therefore, use of such resin particles is especiallypreferred in the present invention.

If necessary, the coating composition of the present invention mayfurther comprise curing catalysts, organic or inorganic coloring orextender pigments customarily used in the field of paints, flash rustingpreventing agents, flow modifiers, defoaming agents,precipitation-preventing agents, antiseptic agents, mildew-proofingagents and other additives, and film-forming resins such aswater-soluble resin, hydrosols and emulsion resins. Since it ispreferred that the softening point of the resin particles be 30° to 100°C., it is preferred that the total amount of the additive componentsthat are not melted at the film-forming temperature be less than 50% byweight.

In the present invention, known non-ionic surface active agents, anionicsurface active agents, cationic surface active agents and amphotericsurface agents can be used as the component (C).

As the non-ionic surface active agent that is used in the presentinvention, there can be mentioned, for example, sorbitan fatty acidesters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylenesorbitol fatty acid esters, polyoxyethylene fatty acid esters,polyoxyethylene alcohol ethers, glycerin fatty acid esters, propyleneglycol fatty acid esters, polyoxyethylene castor oil derivatives,polyoxyethylene alkylphenyl ethers, alkyl phosphates and polyoxyethylephosphates. As the anionic surface acitve agent, there can be mentioned,for example, salts of alkyl sulfates, salts of polyoxyethylene alkylether sulfates, salts of alkyl sulfosuccinates and N-acylsarcosinesalts. As the cationic surface active agent, there may be employed, forexample, quaternary ammonium salts and pyridium salts.

From the viewpoints of the dispersion stability of the resin particlesand properties of the resulting coating, it is preferred to use anon-ionic surface active agent, especially one having an HLB value of 8to 18.

Any of thickeners customarily used for conventional aqueous resin paintscan be used instead of or in combination with the surface active agentas the component (C) in the present invention.

As the thickener that can be used in the present invention, there can bementioned, for example, cellulose type water-soluble resins such asmethyl cellulose, ethyl cellulose and hydroxyethyl cellulose, polyvinylalcohol, polyethylene type water-soluble resins such as polyethyleneglycol ether and polyethylene oxide, maleic anhydride copolymer typewater-soluble resins such as methyl vinyl ether-maleic anhyridecopolymers, ethylene-maleic anhydride copolymers and styrene-maleicanhydride copolymers, ammonium, amine and sodium salts of acrylic acidtype polymers, bentonite, polyvinyl pyrrolidone, alginic acid salts,polyacryloamide and partial hydrolysis products thereof, and naturalwater-soluble resins such as casein and gelatin.

The surface active agent and/or thickener is incorporated in an amountof 0.01 to 1.0% by weight based on the fine resin particles. If theamount of the surface active agent and/or thickener is less than 0.01%by weight, storage stability and adaptibility to the coating workabilityare degraded. If the amount of the surface active agent and/or thickeneris larger than 1.0% by weight, the resulting coating is poor insmoothness and water resistance.

Among the above-mentioned thickeners, an amine salt of a carboxylgroup-containing acrylic copolymer is especially preferred, because theresin is rendered water-insoluble by isolation of the amine underheating at the film-forming step and this resin does not degrade thewater resistance of the resulting coating at all.

In the coating composition of the present invention, it is preferredthat the mixing weight ratio of water to the fine resin particles be inthe range of from 90/10 to 30/70.

If the amount of the resin particles is less than in the above mixingweight ratio range, since the solid concentration in the coatingcomposition is too low and the viscosity is insufficient, if the coatingcomposition is coated to an ordinary thickness, for example, 20 to 80μ,by one coating operation, sagging is caused in the coating, and in orderto avoid this defect, the coating operation should be conducted severaltimes repeatedly. Accordingly, in this case, the adaptability to thecoating workability is drastically lowered.

On the other hand, if the amount of the resin particles exceeds theabove-mentioned mixing weight ratio range, homogenization is hardlyattained by agitation or kneading at the paint-preparing step and theviscosity is outside the range suitable for various coating methods suchas spray coating and electrostatic coating methods, and therefore, theadaptability to the coating workability is degraded and the practicalutility of the coating composition is reduced.

Various known coating methods such as brush coating, dip coating, spraycoating, electrostatic coating, curtain flow coating, shower coating androll coating methods may be used for coating the aqueous dispersion typethermosetting coating composition of the present invention.

Conditions for heating and curing the coating composition of the presentinvention after the coating treatment vary to some extent depending onthe contents of cross-linkable functional groups contained in thecomposition, the desired coating thickness and other factors, butordinarily, a cured coating can be obtained by conducting the heattreatment at an appropriate temperature within the range of from 120° to200° C. for 10 to 40 minutes.

The cured coating has both the merits of the polyester resin, such asgood flexibility, good pigment dispersibility and good coatingappearance, and the merits of the vinyl copolymer resin, such as highhardness and good stain resistance. Futhermore, yellowing or poppingfrequently caused when baking is conducted at a high temperature do notoccur at all in the case of the coating composition of the presentinvention, and a cured coating having excellent properties can beobtained.

The present invention will now be described in detail with reference tothe following Examples that by no means limit the scope of theinvention.

In these Examples, all of "parts" and "%" are by weight.

The preparation of unsaturated polyester resin solutions,polyester-modified vinyl resin solutions and cross-linkable copolymerresin solutions used in Examples are first described.

[Preparation of Unsaturated Polyester Resin Solutions]

(1) Unsaturated polyester resin No. 1 (hereinafter referred to as"PE-1"):

A reaction vessel equipped with a stirrer, a thermometer, a cooling tubeand a nitrogen gas-introducing tube was charged with 32.6 parts ofisophthalic acid, 18.7 parts of adipic acid, 3.0 parts of fumaric acid,29.0 parts of neopentyl glycol and 16.7 parts of trimethylol propane,and the reaction was carried out at 225° C. for about 8 hours under anitrogen gas atmosphere to obtain a resin having an acid value of 15.1,a hydroxyl value of 155 and a weight average molecular weight of 6,700.The resin was diluted with methylethyl ketone so that the non-volatilecomponent content was 60%, to form an unsaturated polyester resinsolution PE-1.

(2) Unsaturated polyester resin No. 2 (hereinafter referred to as"PE-2"):

The same reaction vessel as used above for the preparation of PE-1 wascharged with 32.3 parts of isophthalic acid, 15.1 parts of adipic acid,3.0 parts of fumeric acid, 22.9 parts of neopentyl glycol, 17.4 parts oftrimethylol propane and 9.3 parts of a glycidyl ester of a synthetictertiary saturated fatty acid (manufactured and sold under the tradename"Cardura E" by Shell Chemicals Co. Ltd.), and the reaction was carriedout at 225° C. for about 8 hours under a nitrogen gas atmosphere toobtain a resin having an acid value of 16.2, a hydroxyl value of 166 anda weight average molecular weight of 4,200. The resin was diluted withmethylethyl ketone so that the non-volatile component content was 60% toobtain an unsaturated polyester resin solution PE-2.

(3) Unsaturated polyester resin No. 3 (hereinafter referred to as"PE-3"):

The reaction was carried out at 225° C. for about 6 hours under anitrogen gas atmosphere in the same manner as described above for thepreparation of PE-1 except that 32.6 parts of ortho-phthalic anhydridewas used instead of 32.6 parts of isophthalic acid, to obtain a resinhaving an acid value of 45, a hydroxyl value of 158 and a weight averagemolecular weight of 2,450. The resin was diluted with methylethyl ketoneso that the non-volatile component content was 60%, to obtain anunsaturated polyester resin solution PE-3. [Preparation ofPolyester-Modified Vinyl Resin Solutions]

(1) A reaction vessel equipped with a stirrer, a thermometer, a droppingfunnel, a cooling tube and a nitrogen gas-introducing tube was chargedwith 270 parts of methylethyl ketone and the temperature was elevated to80° C., and a liquid mixture comprising 200 parts of methylmethacrylate, 150 parts of ethyl acrylate, 45 parts of 2-hydroxyethylmethacrylate, 5 parts of acrylic acid, 100 parts of the above-mentionedpolyester resin PE-1 and 6 parts of azobisisobutyronitrile was addeddropwise over a period of 3 hours. After completion of the dropwiseaddition, 1 part of azobisisobutyronitrile was further added, and thereaction temperature was elevated to 87° C. and the reaction was carriedout for 4 hours to obtain a resin solution having a non-volatilecomponent content of 62.0%. The resin was found to have an acid value of11.6, a hydroxyl value of 110, a weight average molecular weight of31,000 and a softening point of about 66° to about 68° C. The so formedresin solution was designated as PE-V-1.

(2) The reaction was carried out in the same manner as described abovefor the preparation of the polyester-modified vinyl resin solutionPE-V-1 except that the polyester resin PE-3 was used instead of thepolyester resin PE-1, to obtain a resin solution having a non-volatilecomponent content of 59.8%. The resin was found to have an acid value of14.9, a hydroxyl value of 118, a weight average molecular weight of33,000 a softening point of about 69° to about 72° C. The so formedresin solution was designated as PE-V-2.

(3) The same reaction vessel as used for the preparation of the resinsolution PE-V-1 was charged with 200 parts of methylethyl ketone and thetemperature was elevated to 80° C., and a liquid mixture comprising 125parts of methyl methacrylate, 10 parts of 2-ethylhexylacrylate, 110parts of 2-ethylhexyl, methacrylate, 45 parts of2-hydroxyethylmethacrylate, 5 parts of acrylic acid, 100 parts of theabove-mentioned polyester resin PE-2 and 6 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1 part ofazobisisobutyronitrile was further added and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of63.1%. The resin was found to have an acid value of 11.3, a hydroxylvalue of 125, a weight average molecular weight of 27,000 and asoftening point of about 70° to about 73° C. This resin solution wasdesignated as PE-V-3.

(4) The reaction was carried out in the same manner as described abovefor the preparation of the polyester-modified vinyl resin solutionPE-V-2 except that the polyester resin PE-2 was used instead of thepolyester resin PE-3 and the amount of the polyester resin was changedto 200 parts, to obtain a resin solution having a non-volatile componentcontent of 60.5%. The resin was found to have an acid value of 12.4, ahydroxyl value of 96, a weight average molecular weight of 49,000 and asoftening point of about 65° to about 68° C. The so formed resinsolution was designated as PE-V-4.

(5) The reaction was carried out in the same manner as described abovefor the preparation of the polyester-modified vinyl resin solutionPE-V-1 except that 200 parts of styrene was used instead of methylmethacrylate and 100 parts of the polyester reisn PE-2 was used insteadof the polyester resin PE-1, to obtain a resin solution having anon-volatile component content of 58.1%. The resin was found to have anacid value 9.1, a hydroxyl value of 115, a weight average molecularweight of 30,000 and a softening point of about 69° to about 72° C. Thisresin solution was designated as PE-V-5.

(6) A reaction vessel equipped with a stirrer, a thermometer, a droppingfunnel, a cooling tube and a nitrogen gas-introducing tube was chargedwith 265 parts of methylethyl ketone and the temperature was elevated at80° C. and a liquid mixture comprising 175 parts of methyl methacrylate,35 parts of styrene, 145 parts of ethyl acrylate, 35 parts of2-hydroxyethyl methacrylate, 5 parts of acrylic acid, 5 parts of acidphosphoxyethyl methacrylate, 100 parts of the above-mentioned polyesterresin PE-2 and 6 parts of azobisisobutyronitrile was added dropwise overa period of 3 hours. After completion of the dropwise addition, I partof azobisisobutyronitrile was further added, and the reactiontemperature was elevated to 87° C. and the reaction was carried out for4 hours to obtain a resin solution having a non-volatile componentcontent of 62.1%. The resin was found to have an acid value of 15.3, ahydroxyl value of 119, a weight average molecular weight of 83,000 and asoftening point of about 79° to about 81° C. Then, trietylamine wasadded to the so formed resin solution in an amount of 2/3 mole per theacid value of the resin to effect neutralization. The resulting resinsolution was designated as PE-PV-1.

(7) The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PE-PV-1 except that the amountof methylethyl ketone was changed to 200 parts, the amount of methylmethacrylate was changed to 133 parts, the amount of styrene was changedto 25.5 parts, the amount of ethyl acrylate was changed to 109 parts,the amount of 2-hydroxyethyl methacrylate was changed to 26 parts, theamount of acrylic acid was changed to 4 parts, the amount of acidphosphoxymethyl methacrylate was changed to 2.5 parts and the amount ofthe polyester resin PE-2 was changed to 200 parts. A resin solutionhaving a non-volatile component content of 61.9% was obtained. The resinwas found to have an acid value of 15.0, a hydroxyl value of 93, aweight average molecular weight of 70,200 and a softening point of about71° to about 74° C. The so formed resin solution was designated asPE-PV- 2.

(8) The same reaction vessel was used for the preparation of PE-PV-1 wascharged with 430 parts of methylethyl ketone and the temperature waselevated to 80° C., and a liquid mixture comprising 157.5 parts ofmethyl methacrylate, 15 parts of styrene, 12.5 parts of 2-ethylhexylacrylate, 180 parts of 2-ethylhexyl methacrylate, 45 parts of2-hydroxyethyl methacrylate, 5 parts of acrylic acid, 5 parts of acidphosphoxyethyl methacrylate, 5 parts of 3-chloro-2-acid-phosphoxypropylmethacrylate, 75 parts of the above-mentioned polyester resin PE-3 and 6parts of azobisisobutyronitrile was added dropwise over a period of 3hours. After completion of the dropwise addition, 1 part ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of50.5%. The resin was found to have an acid value of 20.6, a hydroxylvalue of 103, a weight average molecular weight of 65,000 and asoftening point of about 69° to about 73° C. Triethylamine was added tothe so formed resin solution in an amount of 2/3 mole per the acid valueof the resin to effect neutralization. The resulting solution wasdesignated as PE-PV-3.

(9) The same reaction as used for the preparation of PE-PV-1 was chargedwith 250 parts of methylethyl ketone and the temperature was elevated to80° C., and a liquid mixture comprising 157 parts of methylmethacrylate, 12.5 parts of 2-ethylhexyl acrylate, 138 parts of2-ethylhexyl methacrylate, 56.5 parts of 2-hydroxyethyl methacrylate, 6parts of acrylic acid, 5 parts of acid phosphoxyethyl methacrylate, 125parts of the polyester resin PE-1 and 7.5 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.2 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of61.5%. The resin was found to have an acid value of 17.7, a hydroxylvalue of 115, a weight average molecular weight of 32,100 and asoftening point of about 67° to about 69° C. Triethylamine was added tothe so obtained resin solution in an amount of 2/3 mole per the acidvalue of the resin to effect neutralization. The resulting resinsolution was designated as PE-PV-4.

(10)The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PE-PV-1 except that the amountof methylethyl ketone, methyl methacrylate, styrene, ethyl acrylate,2-hydroxyethyl methacrylate, acrylic acid, acid phosphoxyethylmethacrylate and the polyester resin PE-2 were changed to 750 parts, 190parts, 50 parts, 180 parts, 10 parts, 5 parts, 25 parts and 40 parts,respectively. A resin solution having a non-volatile component contentof 39.8% was obtained. The resin was found to have an acid value of23.1, a hydroxyl value of 35, a weight average molecular weight of34,200 and a softening point of about 71° to about 74° C. Triethylaminewas added to the so obtained resin solution in an amount of 3/4 mole perthe acid value of the resin to effect neutralization. The resultingsolution was designated as PE-PV-5.

(11) The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PE-PV-1 except that 5 parts ofacid phosphoxyethylacrylate was used instead of 5 parts of acidphosphoxyethyl methacrylate, to obtain a resin solution having anon-volatile component of 61.6%. The resin was found to have an acidvalue of 14.8, a hydroxyl value of 110, a weight average molecularweight of 80,500 and a softening point of about 78° to about 80° C.Triethylamine was added to the so formed resin solution in an amount of2/3 mole per the acid value of the resin to effect neutralization. Theresulting resin solution was designated as PE-PV-6.

(12) A reaction vessel equipped with a stirrer, a thermometer a droppingfunnel, a cooling tube and a nitrogen gas-introducing tube was chargedwith 300 parts of methylethyl ketone and the temperature was elevated to80° C., and a liquid mixture comprising 75 parts of methyl methacrylate,140 parts of styrene, 165 parts of ethyl acrylate, 10 parts of2-hydroxyethyl methacrylate, 10 parts of acrylic acid, 50 parts of N-nbutoxymethyl acrylamide, 50 parts of the polyester resin PE-1 and 6parts of azobisisobutyronitrile was added dropwise over a period of 3hours. After completion of the dropwise addition, 1 part ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of57.5%. The resin was found to have an acid value of 16.2, a hydroxylvalue of 40.5, a weight average molecular weight of 61,500 and asoftening point of about 66° to about 68° C. The so formed resinsolution was designated as PE-AV-1.

(13) The same reaction vessel as used for the preparation of the resinsolution PE-AV-1 was charged with 280 parts of methylethyl ketone andthe temperature was elevated to 80° C., and a liquid mixture comprising60 parts of methyl methacrylate, 145 parts of styrene, 155 parts ofethyl acrylate, 5 parts of 2-hydroxyethyl methacrylate, 10 parts ofacrylic acid, 50 parts of N-n-butoxymethyl acrylamide, 75 parts of thepolyester resin PE-2 and 6 parts of azobisisobutyronitrile was addeddropwise over a period of 3 hours. After completion of the dropwiseaddition, 1 part of azobisisobutyronitrile was further added, and thereaction temperature was elevated to 87° C. and the reaction was carriedout for 4 hours to obtain a resin solution having a nonvolatilecomponent content of 58.1%. The resin was found to have an acid value of17.4, a hydroxyl value of 67.0, a weight average molecular weight of135,100 and a softening point of abut 67° to about 69° C. The so formedresin solution was designated as PE-AV-2.

(14) The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PE-AV-2 except that theamounts of methyethyl ketone, ethyl acrylate, 2-hydroxyethylmethacrylate, N-n-butoxymethyl acrylamide and the polyester resin PE-2were changed to 300 parts, 150 parts, 10 parts 75 parts and 50 parts,respectively. A resin solution having a non-volatile component contentof 57.3% was obtained. The resin was found to have an acid value of16.8%, a hydroxyl value of 42.5, a weight average molecular weight of72,100 and a softening point of about 64° to about 67° C. The soobtained resin solution was designated as PE-AV-3.

(15) The same reaction vessel as used for the preparation of the resinsolution PE-AV-1 was charged with 280 parts of methylethyl ketone andthe temperature was elevated to 80° C., and a liquid mixture comprising50 parts of methyl methacrylate, 135 parts of styrene, 145 parts ofethyl acrylate, 10 parts of 2-hydroxyethyl methacrylate, 10 parts ofacrylic acid, 75 parts of N-n-butoxymethyl acrylamide, 75 parts of thepolyester resin PE-3 and 6 parts of azobisisobutyronitrile was addeddropwise over a period of 3 hours. After completion of the dropwiseaddition, 1 part of azobisisobutyronitrile was further added, and thereaction temperature was elevated to 87° C. and the reaction was carriedout for 4 hours to obtain a resin solution having a non-volatilecomponent content of 58.2%. The resin was found to have an acid value of15.1, a hydroxyl value of 61.0, a weight average molecular weight of97,500 and a softening point of about 63° to about 65° C. The soobtained resin solution was designed as PE-AV-4. [Preparation ofCross-Linkable Copolymer Resin Solutions]

(1) A reaction vessel equipped with a stirrer, a thermometer, a droppingfunnel, a cooling tube and a nitrogen gas-introducing tube was chargedwith 340 parts of methyethyl ketone and the temperature was elevated to80° C., and a liquid mixture comprising 50 parts of methyl methacrylate,150 parts of styrene, 165 parts of ethyl acrylate, 125 parts ofN-n-butoxymethyl acrylamide, 10 parts of acrylic acid and 10 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.5 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of58.4%. The resin was found to have an acid value of 12.0, a weightaverage molecular weight of 38,000 and a softening point of about 73° toabout 75° C. The so obtained resin solution was designated as V-1.

(2) The same reaction vessel as used for the preparation of the resinsolution V-1 was charged with 340 parts of methylethyl ketone and thetemperature was elevated to 80° C., and a liquid mixture comprising 150parts of methyl methacrylate, 65 parts of styrene, 175 parts of ethylacrylate, 100 parts of N-n-butoxymethyl acrylamide, 10 parts of acrylicacid and 10 parts of azobisisobutyronitrile was added dropwise over aperiod of 3 hours. After completion of the dropwise addition, 1.5 partsof azobisisobutyronitrile was further added, and the reactiontemperature was elevated to 87° C. and the reaction was carried out for4 hours to obtain a resin solution having a non-volatile content of59.0%. The resin was found to have an acid value of 13.9, a weightaverage molecular weight of 42,000 and a softening point of about 72° toabout 75° C. The so formed resin solution was designated as V-2.

(3) A reaction vessel equipped with a stirrer, a thermometer, a droppingfunnel, a cooling tube and a nitrogen gas-introducing tube was chargedwith 340 parts of methylethyl ketone and the temperature was elevated to80° C., and a liquid mixture comprising 190 parts of methylmethacrylate, 80 parts of styrene, 210 parts of ethyl acrylate, 10 partsof 2-hydroxyethyl methacrylate, 5 parts of acid phosphoxyethylmethacrylate, 5 parts of acrylic acid and 10 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.5 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of59.0%. The resin was found to have an acid value of 11.4, a weightaverage molecular weight of 25,000 and a softening point of about 71° toabout 73° C. Triethylamine was added to the so formed resin solution inan amount of 2/3 mole per the acid value of the resin to effectneutralization. The resulting resin solution was designated as PV-1.

(4) The same reaction vessel as used for the preparation of the resinsolution PV-1 was charged with 340 parts of methylethyl ketone and thetemperature was elevated to 80° C., and a liquid mixture comprising 190parts of methyl methacrylate, 70 parts of styrene, 215 parts of ethylacrylate, 10 parts of 2-hydroxyethyl methacrylate, 10 parts of acidphosphoxyethyl methacrylate, 5 parts of acrylic acid and 10 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.5 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of59.0%. The resin was found to have an acid value of 13.7, a weightaverage molecular weight of 30,800 and a softening point of about 72° toabout 75° C. Triethylamine was added to the so formed resin solution inan amount of 2/3 mole per the acid value of the resin to effectneutralization. The resulting resin solution was designated as PV-2.

(5) The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PV-2 except that the amountsof ethyl acrylate and acid phosphoxethyl methacrylate were changed to200 parts and 25 parts, respectively, to obtain a resin solution havinga non-volatile component content of 60.1%. The resin was found to havean acid value of 28.8, a weight average molecular weight of 31,100 and asoftening point of about 73° to about 76° C. Triethylamine was added tothe so obtained solution in an amount of 3/4 mole per the acid value ofthe resin to effect neutralization. The resulting resin solution wasdesignated as PV-3.

(6) The same reaction vessel as used for the preparation of the resinsolution PV-1 was charged with 750 parts of methylethyl ketone and thetemperature was elevated to 80° C., and a liquid mixture comprising 190parts of methyl methacrylate, 55 parts of styrene, 195 parts of ethylacrylate, 15 parts of 2-hydroxyethyl methacrylate, 40 parts of acidphosphoxyethyl methacrylate, 5 parts of acrylic acid and 10 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.5 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of39.5%. The resin was found to have an acid value of 31.6, a weightaverage molecular weight of 22,500 and a softening point of about 73° toabout 76° C. Triethylamine was added to the so formed resin solution inan amount of 3/4 mole per the acid value of the resin to effectneutralization. The resulting resin solution was designated as PV-4.

(7) The same reaction vessel as used for the preparation of the resinsolution PV-1 was charged with 340 parts of methylethyl ketone and thetemperature was elevated to 80° C., and a liquid mixture comprising 190parts of methyl methacrylate, 70 parts of styrene, 215 parts of ethylacrylate, 10 parts of 2-hydroxyethyl methyacrylate, 5 parts of acidphosphoxyethyl methacrylate, 5 parts of 3-chloro-2-acid-phosphoxypropylmethacrylate, 5 parts of acrylic acid and 10 parts ofazobisisobutyronitrile was added dropwise over a period of 3 hours.After completion of the dropwise addition, 1.5 parts ofazobisisobutyronitrile was further added, and the reaction temperaturewas elevated to 87° C. and the reaction was carried out for 4 hours toobtain a resin solution having a non-volatile component content of59.3%. The resin was found to have an acid value of 14.5, a weightaverage molecular weight of 33,100 and a softening point of about 73° toabout 75° C. Triethylamine was added to the so obtained resin solutionin an amount of 2/3 mole per the acid value of the resin to effectneutralization. The resulting resin solution was designated as PV-5.

(8) The reaction was carried out in the same manner as described abovefor the preparation of the resin solution PB-1 except that 5 parts ofacid phosphoxyethyl acrylate was used instead of 5 parts of acidphosphoxyethyl methacrylate, to obtain a resin solution having anon-volatile component content of 58.9%. The resin was found to have anacid value of 11.9, a weight average molecular weight of 28,900 and asoftening point of about 72° to about 74° C. Triethylamine was added tothe so obtained solution in an amount of 3/4 mole per the acid value ofthe resin to effect neutralization. The resulting resin solution wasdesignated as PV-6.

EXAMPLE 1

To 24 parts of the resin solution PE-V-1 were added 12 parts of titaniumdioxide and 4.5 parts of methyethyl ketone, and the mixture wasdispersed by a sand mill so that the dispersed particle size was smallerthan 10μ (as measured according to the grind gauge; the same will applyhereinafter). Then, the dispersed mixture was mixed under agitation with56 parts of the resin solution V-1 and 3.5 parts of methylethyl ketoneto form a homogeneous pigment dispersion. The dispersion was droppedinto 2000 parts of water maintained at 15° C. and agitated at a highspeed to emulsify the pigment dispersion, extract the solvent into waterand form resin particles. Filtration and water washing were repeated toobtain a water-containing cake of resin particles having an averageparticle size of about 100 μ. The water content in the cake was about50%. To 100 parts of the so obtained water-containing cake were added0.3 part of a 40% aqueous solution of a non-ionic surface active agent(manufactured and sold under the tradename "Emalgen 930" by Kao AtlasCo. Ltd. and having an HLB value of 15.1) and 2 parts of a 10% aqueoussolution of a thickener composed of an alkali metal salt of an acrylicacid type copolymer, and the mixture was dispersed and kneaded by a sandmill to finely pulverize the resin particles. A slurry paint containingresin particles having an average particle size of 15 μ and having a pHvalue of 7.5 was thus obtained.

EXAMPLE 2

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.2 was prepared in the same manneras described in Example 1 except that the resin solution PE-V-2 was usedinstead of the resin solution PE-V-1 used in Example 1.

EXAMPLE 3

To 24 parts of the resin solution PE-V-3 were added 12 parts of titaniumdioxide and 4.5 parts of methylethyl ketone, and the mixture wasdispersed by a sand mill so that the dispersed particle size was smallerthan 10μ. The dispersed mixture was mixed under agitation with 16 partsof the resin solution PE-V-3, 40 parts of the resin solution V-1 and 3.5parts of methylethyl ketone to form a homogeneous pigment dispersion.The dispersion was sprayed into 3000 parts of water maintained at 20° C.and agitated at a high speed to emulsify the pigment dispersion, extractthe solvent into water and form resin particles. Filtration and waterwashing were repeated to obtain a water-containing cake of resinparticles having an average particle size of 150μ. The water content inthe cake was about 50%. To 100 parts of the so obtained cake were added0.4 part of a 40% aqueous solution of a non-ionic surface active agent(manufactured and sold under tradename " Emalgen 910" by Kao Atlas Co.Ltd. and having an HLB value of 12.2) and 4 parts of a 5% aqueoussolution of a thickener (hydroxyethyl cellulose), and the mixture wasdispersed by a ball mill to finely pulverize the resin particles. Aslurry paint containing resin particles having an average particle sizeof 15μ and having a pH value of 7.6 was thus obtained.

EXAMPLE 4

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.5 was prepared in the same manneras described in Example 3 except that the resin solution PE-V-4 was usedinstead of the resin solution PE-V-3 used in Example 3.

EXAMPLE 5

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.3 was prepared in the same manneras described in Example 1 except that the amount of the resin solutionPE-V-1 was changed to 40 parts from 24 parts and the amount of the resinsolution V-1 was changed to 40 parts from 56 parts.

EXAMPLE 6

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.5 was prepared in the same manneras described in Example 3 except that the amount of the resin solutionPE-V-3 was changed to 8 parts from 40 parts and the amount of the resinsolution V-1 was changed to 72 parts from 40 parts.

EXAMPLE 7

To 24 parts of the resin solution PE-V-5 were added 12 parts of titaniumdioxide, 0.5 part of a flow modifier (manufactured and sold under thetradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0 parts ofmethylethyl ketone, and the mixture was dispersed by a sand mill so thatthe dispersed particle size was smaller than 10μ. Then, 56 parts of theresin solution V-2 and 3.5 parts of methylethyl ketone were added to thedispersed mixture, and the resulting mixture was blended under agitationto form a pigment dispersion. The dispersion was dropped into 2000 partsof water maintained at 15° C. and agitated at a high speed to emulsifythe pigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeof about 100μ. The water content in the cake was about 50%. To 100 partsof the so obtained water-containing cake were added 0.2 part of a 50%aqueous solution of a non-ionic surface active agent (manufactured andsold under the tradename "Emalgen 935" by Kao Atlas Co. Ltd. and havingan HLB value of 17.5) and 2 parts of a 10% aqueous solution of athickener composed of an alkali metal salt of an acrylic acid typecopolymer, and the mixture was dispersed by a sand mill to finelypulverize the resin particles. A slurry paint containing resin particleshaving an average particle size of 13μ and having a pH value 7.3 wasthus obtained.

COMPARATIVE EXAMPLE 1

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-V-1used in Example 1 except that the modifying polyester resin PE-1 was notused, to obtain a resin solution having a non-volatile component contentof 60.2%. The resin was found to have an acid value of 11.3, a hydroxylvalue of 53 and a weight average molecular weight of 11,500. To 24 partsof the so obtained resin solution were added 12 parts of titaniumdioxide and 4.5 parts of methylethyl ketone, and the mixture wasdispersed so that the dispersed particle size was smaller than 10μ.Then, the so dispersed mixture was mixed with 36 parts of the aboveresin solution, 20 parts of a 60% methyethyl ketone solution of abutylated methylol-melamine resin having an average condensation degreeof 2.5, an etherification degree of 2.5 and a water-soluble componentcontent lower than 1% and 3.5 parts of methylethyl ketone, and theresulting mixture was blended and agitated to form a homogeneous pigmentdispersion. The dispersion was then treated in the same manner asdescribed in Example 1, to obtain a slurry paint containing resinparticles having an average particle size of 15μ and having a pH valueof 7.7.

COMPARATIVE EXAMPLE 2

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-V-3used in Example 3 except that the polyester resin PE-2 was not used, toobtain a resin solution having a non-volatile component content of59.8%. The resin was found to have an acid value of 11.9, a hydroxylvalue of 55 and a weight average molecular weight of 13,100. To 24 partsof the so obtained resin solution were added 12 parts of titaniumdioxide and 4.5 parts of methylethyl ketone, and the mixture wasdispersed by a ball mill so that the dispersed particle size was smallerthan 10μ. To the dispersed mixture were added 41 parts of the aboveresin solution, 15 parts of a blocked isocyanate resin (manufactured andsold under the tradename "Crelan Ue 6109" by Bayer AG), 0.5 part ofdibutyltin dilaurate (dissociation catalyst) and 3 parts of methylethylketone, and the resulting mixture was blended and agitated to obtain ahomogeneous pigment dispersion. The so formed dispersion was thentreated in the same manner as described in Example 3 to obtain a slurrypaint containing resin particles having an average particle size of 15μand having a pH value of 7.5.

COMPARATIVE EXAMPLE 3

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.3 was prepared in the same manneras described in Example 3 except that the vinyl resin solution used inComparative Example 2 was used instead of the resin solution RE-V-3 usedin Example 3.

The slurry paints obtained in Examples 1 to 7 and Comparative Examples 1to 3 were independently spray-coated on polished soft steel plates,pre-heated at 90° C. for 10 minutes and heated and dried at apredetermined temperature to obtain coatings having a thickness of about35μ. Baking conditions and the results of tests of physical propertiesof the resulting coatings are shown in Table 1.

                                      TABLE 1                                     __________________________________________________________________________                Ex- Ex- Ex- Ex- Ex-                                                           ample                                                                             ample                                                                             ample                                                                             ample                                                                             ample                                                                             Example                                                                            Example                                                                            Comparative                                                                          Comparative                                                                          Comparative                       1   2   3   4   5   6    7    Example 1                                                                            Example                                                                              Example               __________________________________________________________________________                                                            3                     Baking Conditions                                                             Temperature (°C.)                                                                  160 200 180 150 170 170  190  160    170    180                   Time (minutes)                                                                            20  20  20  20  20  20   20   20     20     20                    Appearance of Coating                                                         Popping.sup.1                                                                             none                                                                              none                                                                              none                                                                              none                                                                              none                                                                              none none observed                                                                             none   none                  Yellowing resistance.sup.2                                                                good                                                                              good                                                                              good                                                                              good                                                                              good                                                                              good good good   poor   poor                  Gloss.sup.3 88  87  89  87  89  87   90   86     88     86                    Physical Properties of                                                        Coating                                                                       Pencil hardness.sup.4                                                                     2H  3H  2H  H   2H  H    2H   3H     H      F                     Adhesion.sup.5                                                                            100/                                                                              100/                                                                              100/                                                                              100/                                                                              100/                                                                              100/100                                                                            100/100                                                                            60/100 95/100 80/100                            100 100 100 100 100                                               Erichsen test.sup.6                                                                       7<  7<  7<  7<  7<  7<   7<   2.0    3.5    5.0                   Impact resistance.sup.50                                                                  >50 >50 40  50  40  50   10   10     20                           Solvent resistance.sup.8                                                                  ⊚                                                                  ⊚                                                                  O   O   O   ⊚                                                                   O    ⊚                                                                     O      X                     Adhesion after humidity                                                                   ⊚                                                                  ⊚                                                                  O   ⊚                                                                  O   O    O    X      O      X                     resistance test.sup.9                                                         __________________________________________________________________________     Note                                                                          .sup.1,2 evaluated based on naked eye observation                             .sup.3 60°/60° specular gloss                                   .sup.4 the point of pencil (Mitsubishi Uni) was put on the coating at an      angle of 45° and lightly pressed forward, and pencil hardness was      expressed by the hardness of hardest pencil that did not leave any trace      on the coating                                                                .sup.5 crosscut adhesive tape peel test                                       .sup.6 tested by using Erichsen tester                                        .sup.7 according to method 3B, JIS K5400, 6-13                                .sup.8 rubbing test using ethyl acetate was conducted 50 times and            delustering degree was examined                                                ⊚  change                                                     O slight delustering                                                          X considerable delustering                                                    .sup.9 crosscut adhesive tape test after 200 hours' humidity resistance       test (50° C., 97% RH< )                                                 ⊚  100/100-90/100                                             O 89/100-60/100                                                               X 59/100-0/100                                                           

EXAMPLE 8

To 24 parts of the resin solution PE-PV-1 were added 12 parts oftitanium dioxide and 4.5 parts of methylethyl ketone, and the mixturewas dispersed so that the dispersed particle size was smaller than 10μ(according to the grind gauge; the same hereinafter). To the dispersedmixture were added 16 parts of the resin solution PE-PV-1, 40 parts ofthe resin solution V-1 and 3.5 parts of methylethyl ketone, and theresulting mixture was blended and agitated to form a homogeneous pigmentdispersion. The dispersion was dropped into 2000 parts of watermaintained at 15° C. and agitated at a high speed to emulsify thepigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeof about 100μ. The water content in the cake was about 50%. To 100 partsof the so obtained cake were added 0.3 part of a 40 % aqueous solutionof a non-ionic surface active agent (manufactured and sold under thetradename "Emalgen 930" by Kao Atlas Co. Ltd. and having an HLB value of15.1) and 2 parts of a 10% aqueous solution of a thickener composed ofan alkali metal salt of an acrylic acid type copolymer, and the mixturewas dispersed by a sand mill to finely pulverize the resin particles. Aslurry pain containing resin particles having an average particle sizeof 16μ and having a pH value of 7.8 was thus obtained.

EXAMPLE 9

A slurry paint containing resin particles having an average particlesize of 16μ and having a pH value of 7.6 was prepared in the same manneras described in Example 8 except that the resin solution PE-PV-2 wasused instead of the resin solution PE-PV-1 used in Example 8.

EXAMPLE 10

To 24 parts of the resin solution PE-PV-3 were added 12 parts oftitanium dioxide and 4.5 parts of methylethyl ketone, and the mixturewas dispersed so that the dispersed particle size was smaller than 10μ.The dispersed mixture was then mixed with 56 parts of the resin solutionV-2 and 3.5 parts of methylethyl ketone, and the resulting mixture wasblended and agitated to obtain a homogeneous pigment dispersion. Thedispersion was sprayed into 3000 parts of water maintained at 20° C. andagitated at a high speed to emulsify the pigment dispersion, extract thesolvent into water and form resin particles. Filtration and waterwashing were repeated to obtain a water-containing cake of resinparticles having an average particle size of 150μ. The water content inthe cake was about 50%. To 100 parts of the so obtained cake were added0.4 part of a 40% aqueous solution of a non-ionic surface active agent(manufactured and sold under the tradename "Emalgen 910" by Kao AtlasCo. Ltd. and having an HLB value of 12.2) and 4 parts of a 5% aqueoussolution of a thickener (hydroxyethyl cellulose), and the mixture wasdispersed and kneaded by a ball mill to finely pulverize the resinparticles. A slurry paint containing resin particles having an averageparticle size of 14μ and having a pH value of 7.9 was thus obtained.

EXAMPLE 11

To 24 parts of the resin solution PE-PV-4 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Then, thedispersed mixture was mixed with 24 parts of the resin solution PE-PV-4,32 parts of the resin solution V-1 and 3.5 parts of methylethyl ketone,and the resulting mixture was blended and agitated to form a homogeneouspigment dispersion. The subsequent operations were conducted in the samemanner as described in Example 8 to obtain a slurry paint containingresin particles having an average particle size of 15μ and having a pHvalue of 7.7.

EXAMPLE 12

To 40 parts of the resin solution PE-PV-5 were added 10 parts oftitanium dioxide and 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.), and themixture was dispersed by a sand mill so that the dispersed particle sizewas smaller than 10μ. The dispersed mixture was mixed with 30 parts ofthe resin solution PE-PV-5, 12 parts of the resin solution V-2 and 7.5parts of methylethyl ketone, and the resulting mixture was blended andagitated to form a homogeneous pigment dispersion. The subsequentoperations were conducted in the same manner as described in Example 8to obtain a slurry paint containing resin particles having an averageparticle size of 14μ and having a pH value of 7.8.

EXAMPLE 13

To 24 parts of the resin solution PE-PV-6 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 8 parts of the resin solution PE-PV-6,48 parts of the resin solution V-1 and 3.5 parts of methylethyl ketone,and the resulting mixture was blended and agitated to form a homogeneouspigment dispersion. The subsequent operations were conducted in the samemanner as described in Example 8 to obtain a slurry paint containingresin particles having an average particle size of 15μ and having a pHvalue of 7.6.

COMPARATIVE EXAMPLE 4

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-PV-1used in Example 8 except that the modifying polyester resin PE-2 was notused and acid phosphoxyethyl methacrylate was not added, to obtain aresin solution having a non-volatile component content of 58.9%. Theresin was found to have an acid value of 11.9, a hydroxyl value of 49and a weight average molecular weight of 12,200. To 24 parts of the soobtained resin solution were added 12 parts of titanium dioxide and 4.5parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 36 parts of the above resin solution,20 parts of a 60% methylethyl ketone solution of a butylatedmethylolmelamine resin having an average condensation degree of 2.5, anetherification degree of 2.5 and a water-soluble component content lowerthan 1% and 3.5 parts of methylethyl ketone, and the resulting mixturewas blended and agitated to form a homogeneous pigment dispersion. Thesubsequent operations were conducted in the same manner as described inExample 8 to obtain a slurry paint containing resin particles having anaverage particle size of 15μ and having a pH value of 7.4.

COMPARATIVE EXAMPLE 5

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-PV-3used in Example 10 except that the polyester resin PE-3 was not used andacid phosphoxyethyl methacrylate and 3-chloro-2-acidphosphoxypropylmethacrylate were not added, to obtain a resin solution having anon-volatile component content of 59.2%. The resin was found to have anacid value of 11.3, a hydroxyl value of 51 and a weight averagemolecular weight of 18,500. To 24 parts of the so obtained resinsolution were added 12 parts of titanium dioxide and 4.5 parts ofmethylethyl ketone, and the mixture was dispersed by a ball mill so thatthe dispersion particle size was smaller than 10μ. The dispersed mixturewas mixed with 41 parts of the above resin solution, 15 parts of ablocked isocyanate resin (manufactured and sold under the tradename"Crelan Ue 6109" by Bayer AG), 0.5 parts of dibutyltin dilaurate(dissociation catalyst) and 3 parts of methylethyl ketone, and theresulting mixture was blended and agitated to form a homogeneous pigmentdispersion. The subsequent operations where conducted in the same manneras described in Example 10 to obtain a slurry paint containing resinparticles having an average particle size of 15μ and having a pH valueof 7.4.

COMPARATIVE EXAMPLE 6

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.4 was prepared in the same manneras described in Example 10 except that the vinyl resin solution used inComparative Example 5 was used instead of the resin solution PE-PV-3used in Example 10.

The slurry paints prepared in Examples 8 to 13 and Comparative Examples4 to 6 were independently spray-coated on polished soft steel plates,set for 5 minutes, pre-heated at 90° C. for 10 minutes and heated anddried at a predetermined temperature to obtain coatings having athickness of about 35μ. The packing conditions and the results of testsof physical properties of the coatings are shown in Table 2.

                                      TABLE 2                                     __________________________________________________________________________                Example                                                                            Example                                                                            Example                                                                            Example                                                                            Example                                                                            Example                                                                            Comparative                                                                          Comparative                                                                          Comparative                       8    9    10   11   12   13   Example 4                                                                            Example                                                                              Example               __________________________________________________________________________                                                            6                     Baking Conditions                                                             Temperature (°C.)                                                                  160  190  150  200  180  180  160    170    180                   Time (minutes)                                                                            20   20   20   20   20   20   20     20     20                    Appearance of Coating                                                         Flash rusting.sup.1                                                                       none none none none none none observed                                                                             observed                                                                             observed              Popping     none none none none none none observed                                                                             none   none                  Yellowing resistance                                                                      good good good good good good good   poor   good                  Gloss       86   88   86   89   86   87   86     88     86                    Physical Properties of                                                        Coating                                                                       Pencil hardness                                                                           2H   3H   H    3H   H    2H   3H     H      F                     Adhesion    100/100                                                                            100/100                                                                            100/100                                                                            100/100                                                                            100/100                                                                            100/100                                                                            60/100 90/100 80/100                Erichsen test                                                                             7<   7<   7<   7<   7<   7<   2.0    3.0    4.0                   Impact resistance                                                                         >50  >50  >50  40   30   >50  10     10     20                    Solvent resistance                                                                        ⊚                                                                   ⊚                                                                   O    ⊚                                                                   O    ⊚                                                                   ⊚                                                                     O      X                     Adhesion after                                                                            ⊚                                                                   ⊚                                                                   ⊚                                                                   ⊚                                                                   ⊚                                                                   ⊚                                                                   X      O      X                     humidity resistance                                                           test                                                                          Adhesion after salt                                                                       ⊚                                                                   ⊚                                                                   ⊚                                                                   ⊚                                                                   O    ⊚                                                                   X      X      X                     spray resistance                                                              test.sup.2                                                                    Storage Stability of                                                                      10<  10<  10<  10<  10<  10<  7      5      5                     Composition.sup.3                                                             __________________________________________________________________________     Note                                                                          .sup.1 evaluated based on naked eye observation during setting                .sup.2 sample crosscut to the substrate was tested for 100 hours by salt      spray tester (JIS Z2371), and crosscut portion was subjected to adhesive      cellophane tape peel test and peel width (on one side) was measured           0-1.0 mm                                                                      1.1-2.0 mm                                                                    2.1-3.0 mm                                                                    X 3.1 mm or more                                                              .sup.3 sample was stored in air bath maintained at 50° C. and          stability was expressed by the number of days which passed without            occurrence of gelation or precipitation                                       Other items are the same as described in Table 1.                        

EXAMPLE 14

To 24 parts of the resin solution PE-AV-1 were added 12 parts oftitanium dioxide and 4.5 parts of methylethyl ketone, and the mixturewas dispersed by a pot mill so that the dispersed particle size wassmaller than 10μ (measured according to the grind gauge; the samehereinafter). The dispersed mixture was mixed with 51 parts of the resinsolution PE-AV-1, 10 parts of the resin solution PV-4 and 3.5 parts ofmethylethyl ketone, and the resulting mixture was blended and agitatedto obtain a homogeneous pigment dispersion. The pigment dispersion wasdropped in 2000 parts of water maintained at 15° C. and agitated at ahigh speed to emulsify the pigment dispersion, extract the solvent intowater and form resin particles. Filtration and water washing wererepeated to obtain a water-containing cake of resin particles having anaverage particle size of about 100μ. The water content in the cake wasabout 50%. To 100 parts of the so obtained cake were added 0.3 part of a40% aqueous solution of a non-ionic surface active agent (manufacturedand sold under the tradename "Emalgen 930" by Kao Atlas Co. Ltd.) and 2parts of a 10% aqueous solution of a thickener composed of an alkalimetal salt of an acrylic acid type copolymer, and the mixture wasdispersed by a sand mill to finely pulverize resin particles. A slurrypaint contaiing resin particles having an average particle size of 15μand having a pH value of 7.7 was thus obtained.

EXAMPLE 15

To 24 parts of the resin solution PE-AV-2 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 40 parts of the resin solution PE-AV-2,16 parts of the resin solution PV-3 and 3.5 parts of methylethyl ketone,and the resulting mixture was blended and agitated to form a homogeneouspigment dispersion. The dispersion was dropped in 2000 parts of watermaintained at 15° C. and agitated at a high speed to emulsify thepigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeof about 100μ. The water content in the cake was about 50%. To 100 partsof the so obtained water-containing cake were added 0.3 part of a 40%aqueous solution of a non-ionic surface active agent (manufactured andsold under the tradename "Emalgen 930" by Kao Atlas Co. Ltd. and havingan HLB value of 15.1) and 2 parts of a 10% aqueous solution of athickener composed of an alkali metal salt of an acrylic acid typecopolymer, and the mixture was dispersed by a sand mill to finelypulverize the resin particles. A slurry paint containing resin particleshaving an average particle size of 15μ and having a pH value of 7.5 wasthus obtained.

EXAMPLE 16

To 24 parts of the resin solution PE-AV-3 were added 12 parts oftitanium dioxide and 4.5 parts of methylethyl ketone, and the mixturewas dispersed by a ball mill so that the dispersed particle size wassmaller than 10μ. The dispersed mixture was mixed with 32 parts of theresin solution PE-AV-3, 24 parts of the resin solution PV-2 and 3.5parts of methylethyl ketone, and the resulting mixture was blended andagitated to form a homogeneous pigment dispersion. The pigmentdispersion was sprayed into 3000 parts of water maintained at 20° C. andagitated at a high speed to emulsify the pigment dispersion, extract thesolvent into water and form resin particles. Filtration and waterwashing were repeated to obtain a water-containing cake of resinparticles having an average particle size of 150μ. The water content inthe cake was about 50%. To 100 parts of the so obtained water-containingcake were added 0.4 parts of a 40% aqueous solution of a non-ionicsurface active agent (manufactured and sold under the tradename "Emalgen910" by Kao Atlas Co. Ltd. and having and HLB value of 12.2) and 4 partsof a 5% aqueous solution of a thickener (hydroxyethyl cellulose), andthe mixture was dispersed and kneaded by a ball mill to finely pulverizethe resin particles. A slurry paint containing resin particles having anaverage particle size of 16μ and having a pH value of 7.8 was thusobtained.

EXAMPLE 17

To 24 parts of the resin solution PE-AV-4 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 8 parts of the resin solution PE-AV-4,48 parts of the resin solution PV-1 and 3.5 parts of methylethyl ketone,and the resulting mixture was blended and agitated to form a homogeneouspigment dispersion. The pigment dispersion was dropped in 2000 parts ofwater maintained at 15° C. and agitated at a high speed to emulsify thepigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeof about 100μ. The water content in the cake was about 50%. To 100 partsof the so obtained water-containing cake were added 0.2 part of a 50%aqueous solution of a non-ionic surface active agent (manufactured andsold under the tradename "Emalgen 935" by Kao Atlas Co. Ltd. and havingan HLB value of 17.5) and 2 parts of a 10% aqueous solution of athickener composed of an alkali metal salt of an acrylic acid thpecopolymer, and the resulting mixture was dispersed by a sand mill tofinely pulverized resin particles. A slurry paint containing resinparticles having an average particle size of 14μ and having a pH valueof 7.7 was thus obtained.

EXAMPLE 18

A slurry paint containing resin particles having an average particlesize of 15μ and having a pH value of 7.6 was prepared in the same manneras described in Example 17 except that the total amount of the resinsolution PE-AV-4 was changed to 40 parts from 32 parts and 40 parts ofthe resin solution PV-2 was used instead of 48 parts of the resinsolution PV-1.

EXAMPLE 19

To 24 parts of the resin solution PE-AV-3 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 32 parts of the resin solution PE-AV-3,24 parts of the resin solution PV-5 and 3.5 parts of methylethyl ketone,and the resulting mixture was blended and agitated to form a homogeneouspigment dispersion. The pigment dispersion was dropped in 2000 parts ofwater maintained at 15° C. and agitated at a high speed to emulsify thepigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeabout 100μ. The water content in the cake was about 50%. To 100 parts ofthe so obtained water-containing cake were added 0.25 part of a 40%aqueous solution of a non-ionic surface active agent (manufactured andsold under the tradename "Emalgen 930" by Kao Atlas Co. Ltd. and havingan HLB value of 15.1) and 1.5 parts of a 10% aqueous solution of athickener composed of an alkali metal salt of an acrylic acid typecopolymer, and the mixture was dispersed by a sand mill to finelypulverize the resin particles. A slurry paint containing resin particleshaving an average particle size of 15μ and having a pH value of 7.7 wasthus obtained.

EXAMPLE 20

To 24 parts of the resin solution PE-AV-4 were added 12 parts oftitanium dioxide, 0.5 part of a flow modifier (manufactured and soldunder the tradename "Modaflow" by Monsanto Chemical Co. Ltd.) and 4.0parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 24 parts of the resin solution PE-AV-4,32 parts of the resin solution PV-6 and 3.5 parts of methylethyl ketone,and the mixture was blended and agitated to form a homogeneous pigmentdispersion. The pigment dispersion was dropped in 2000 parts of watermaintained at 15° C. and agitated at a high speed to emulsify thepigment dispersion, extract the solvent into water and form resinparticles. Filtration and water washing were repeated to obtain awater-containing cake of resin particles having an average particle sizeof about 100μ. The water content in the cake was about 50%. To 100 partsof the so obtained water-containing cake were added 0.2 part of a 40%aqueous solution of a non-ionic surface active agent (manufactured andsold under the tradename "Emalgen 930" by Kao Atlas Co. Ltd. and havingan HLB value of 15.1) and 1.5 parts of a 10% aqueous solution of athickener composed of an alkali metal salt of an acrylic acid typecopolymer, and the mixture was dispersed by a sand mill to finelypulverize the resin particles. A slurry paint containing resin particleshaving an average particle size of 16μ and having a pH value of 7.5 wasthus obtained.

COMPARATIVE EXAMPLE 7

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-AV-1used in Example 14 except that the modifying polyester resin PE-1 wasnot used and N-n-butoxymethyl acrylamide was not added, to obtain aresin solution having a non-volatile compoent content of 58.4%. Theresin was found to have an acid value of 12.3, a hydroxyl value of 27and a weight average molecular weight of 71,500. To 24 parts of the soformed resin solution were added 12 parts of titanium dioxide and 4.5parts of methylethyl ketone, and the mixture was dispersed by a sandmill so that the dispersed particle size was smaller than 10μ. Thedispersed mixture was mixed with 44 parts of the above resin solution,12 parts of a 60% methylethyl ketone solution of a butylatedmethylol-melamine resin having an average condensation degree of 2.5, anetherification degree of 2.5 and a water-soluble component content lowerthan 1 % and 3.5 parts of methylethyl ketone, and the resulting mixturewas blended and agitated to form a homogeneous pigment dispersion. Thesubsequent operations were conducted in the same manner as described inExample 14, to obtain a slurry paint containing resin particles havingan average particle size of 15μ and having a pH value of 7.5.

COMPARATIVE EXAMPLE 8

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin PE-AV-3 used inExample 16 except that the polyester resin PE-2 was not used andN-n-butoxymethyl acrylamide was not added, to obtain a resin solutionhaving a non-volatile component content of 59.1%. The resin was found tohave an acid value of 12.2, a hydroxyl value of 33 and a weight averagemolecular weight of 16,200. To 24 parts of the so formed resin solutionwere added 12 parts of titanium dioxide and 4.5 parts of methylethylketone, and the mixture was dispersed by a ball mill so that thedispersed particle size was smaller than 10μ. The dispersed mixture wasmixed with 48 parts of the above resin solution, 8 parts of a blockedisocyanate resin (manufactured and sold under the tradename "Crelan Ue6109" by Bayer AG), 0.5 part of dibutyltin dilaurate (dissociationcatalyst) and 3 parts of methylethyl ketone. The resulting mixture wasblended and aditated to form a homogeneous pigment dispersion. Thesubsequent operations were conducted in the same manner as described inExample 16, to obtain a slurry paint containing resin particles havingan average particle size of 15μ and having a pH value of 7.3.

COMPARATIVE EXAMPLE 9

The reaction was carried out in the same manner as described above forthe preparation of the polyester-modified vinyl resin solution PE-AV-1used in Example 14 except that the modifying polyester resin PE-1 wasnot used, to form a resin solution having a non-volatile componentcontent of 58.7%. The resin was found to have an acid value of 13.6, ahydroxyl value of 30.5 and a weight average molecular weight of 41,000.To 24 parts of the so obtained resin solution were added 12 parts oftitanium dioxide and 4.5 parts of methylethyl ketone, and the mixturewas dispersed by a ball mill so that the dispersed particle size wassmaller than 10μ. The dispersed mixture was mixed with 56 parts of theabove resin solution and 3.5 parts of methylethyl ketone, and theresulting mixture was blended and agitated to form a homogeneous pigmentdispersion. The subsequent operations were conducted in the same manneras described in Example 14, to obtain a slurry paint containing resinparticles having an average particle size of 15μ and having a pH valueof 7.4.

The slurry paints prepared in Examples 14 to 20 and Comparative Examples7 to 9 were independently spray-coated on polished soft steel plates,set for 5 minutes, pre-heated at 90° C. for 10 minutes and heated anddried at a predetermined temperature to obtain coatings having athickness of about 35μ. The baking conditions and results of tests ofphysical properties of the coatings are shown in Table 3.

                                      TABLE 3                                     __________________________________________________________________________                Ex- Ex- Ex- Ex- Ex-                                                           ample                                                                             ample                                                                             ample                                                                             ample                                                                             ample                                                                             Example                                                                            Example                                                                            Comparative                                                                          Comparative                                                                          Comparative                       14  15  16  17  18  19   20   Example 7                                                                            Example                                                                              Example               __________________________________________________________________________                                                            9                     Baking Conditions                                                             Temperature (°C.)                                                                  170 160 170 200 180 190  190  160    170    180                   Time (minutes)                                                                            20  20  20  20  20  20   20   20     20     20                    Appearance of Coating                                                         Flash rusting                                                                             none                                                                              none                                                                              none                                                                              none                                                                              none                                                                              none none observed                                                                             observed                                                                             observed              Popping     none                                                                              none                                                                              none                                                                              none                                                                              none                                                                              none none observed                                                                             none   none                  Yellowing resistance                                                                      good                                                                              good                                                                              good                                                                              good                                                                              good                                                                              good good good   poor   good                  Gloss       88  86  89  88  89  89   88   88     88     87                    Physical Properties of                                                        Coating                                                                       Pencil hardness                                                                           2H  2H  2H  3H  2H  3H   2H   3H     H      H                     Adhesion    100/                                                                              100/                                                                              100/                                                                              100/                                                                              100/                                                                              100/100                                                                            100/100                                                                            40/100 65/100 70/100                            100 100 100 100 100                                               Erichsen test                                                                             5<  5<  5<  5<  5<  5<   5<   2.0    3.0    3.5                   Impact resistance                                                                         50  50  50  40  50  50   50   10     10     10>                   Solvent resistance                                                                        O   O   ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                   ⊚                                                                   ⊚                                                                     O      X                     Adhesion after humidity                                                                   ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                   ⊚                                                                   x      O      x                     resistance test                                                               Adhesion after salt                                                                       O   ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                  ⊚                                                                   ⊚                                                                   X      X      X                     spray resistance                                                              test                                                                          Storage Stability of                                                                      10< 10< 10< 10< 10< 10<  10<  6      5      5                     Composition                                                                   __________________________________________________________________________     Note                                                                          The respective items are the same as described in Tables 1 and 2.        

What is claimed is:
 1. An aqueous dispersion type thermosetting coatingcomposition comprising (A) fine .[.thermosetting.]. water-insoluble.Iadd.thermosetting .Iaddend.resin particles consisting essentially of(a) a preformed polyester-modified vinyl resin having a hydroxyl valueof 30 to 200, which is formed by solution graft-polymerizing (i) anunsaturated polyester resin formed by .[.reaction between an.]..Iadd.reacting 1-10% by weight of at least one α,β-.Iaddend.unsaturateddicarboxylic acid.Iadd., at least one carboxylic acid component selectedfrom the group consisting of phthalic acid, phthalic anhydride,isophthalic acid, isophthalic anhydride, trimellitic acid, trimelliticanhydride, pyromellitic acid, pyromellitic anhydride, tetrahydrophthalicacid, tetrahydrophthalic anhydride, hexahydrophthalic acid,hexahydrophthalic anhydride, methylhexahydrophthalic acid,methylhexahydrophthalic anhydride, 3,6-endomethylene-tetrahydrophthalicanhydride, succinic acid, succinic anhydride, adipic acid, sebacic acid,benzoic acid and p-tert-butyl-benzoic acid .Iaddend.and .[.a.]. .Iadd.atleast one .Iaddend.polyhydric alcohol, with (ii) at least oneα,β-monoethylenically unsaturated monomer, and optionally with (iii) aphosphoric acid group-containing α,β-monoethylenically unsaturatedmonomer, and (b) a performed cross-linkable copolymer resin derived froma monomer mixture comprising (iv) an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide and (ii) atleast one α,β-monoethylenically unsaturated monomer, (B) a surfaceactive agent and/or a thickener, and (C) a necessary amount of water. 2.An aqueous dispersion type thermosetting coating composition as setforth in claim 1, wherein said (A) fine water-insoluble thermosettingresin particles consist essentially of 5 to 90% by weight of saidpolyester-modified vinyl resin having a hydroxyl value of 30 to 200,which is formed by solution graft-polymerizing (i) 5 to 50% by weight ofsaid unsaturated polyester resin with (ii) 95 to 50% by weight of atleast one said α,β-monoethylenically unsaturated monomer and 95 to 10%by weight of said cross-linkable copolymer resin, and said (B) surfaceactive agent and/or thickener is present in an amount of .[.0.1.]..Iadd.0.01 .Iaddend.to 1.0% by weight based on said resin particles..[.3. An aqueous dispersion type thermosetting coating composition asset forth in claim 2 wherein said unsaturated polyester resin comprises1 to 10% by weight of at least one α,β-unsaturated dicarboxylic acid asone constituent..].
 4. An aqueous dispersion type thermosetting coatingcomposition as set forth in claim 2 wherein the α,β-monoethylenicallyunsaturated monomer graft-polymerized with said unsaturated polyesterresin is a monomer mixture comprising (ii)' 5 to 50% by weight of ahydroxyalkyl ester of an α,β-monoethylenically unsaturated carboxylicacid and (ii)" 95 to 50% by weight of a copolymerizableα,β-monoethylenically unsaturated monomer other than said monomer (ii)'.5. An aqueous dispersion type thermosetting coating composition as setforth in claim 2 wherein said cross-linkable copolymer resin is derivedfrom a monomer mixture comprising (iv) 5 to 30% by weight of anN-alkoxymethylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid amide, (ii)'" 0.5 to 10% by weight anα,β-monoethylenically unsaturated carboxylic acid and (ii)"" 60 to 90%by weight of a copolymerizable α,β-monoethylenically unsaturated monomerother than said monomers (iv) and (ii)'".
 6. An aqueous dispersion typethermosetting coating composition as set forth in claim 1 wherein said(A) fine water-insoluble thermosetting resin particles consistessentially of (a) 5 to 90% by weight of said polyestermodified vinylresin having a hydroxy value of 30 to 200, which is formed by solutiongraft-polymerizing (i) 2 to 50% by weight of said unsaturated polyesterresin with (ii) 95 to 40% by weight of at least one saidα,β-monoethylenically unsaturated monomer and (iii) 0.01 to 10% byweight of said phosphoric acid group-containing α,β-monoethylenicallyunsaturated monomer and (b) 95 to 10% by weight of said cross-linkablecopolymer resin, and said (B) surface active agent and/or thickener ispresent in an amount of 0.01 to 1.0% by weight based on said resinparticles. .[.7. An aqueous dispersion type thermosetting coatingcomposition as set forth in claim 6 wherein said unsaturated polyesterresin comprises 1 to 10% by weight of at least one α,β-unsaturateddicarboxylic acid as one constituent..].
 8. An aqueous dispersion typethermosetting coating composition as set forth in claim 6 wherein theα,β-monoethylenically unsaturated monomer graft-polymerized with saidunsaturated polyester resin is a monomer mixture comprising (ii)' 1 to40% by weight of a hydroxyalkyl ester of an α,β-monoethylenicallyunsaturated carboxylic acid and (ii)" 99 to 60% by weight of acopolymerizable α,β-monoethylenically unsaturated monomer other thansaid monomer (ii)'.
 9. An aqueous dispersion type thermosetting coatingcomposition as set forth in claim 6 wherein said cross-linkablecopolymer resin is derived from a monomer mixture comprising (iv) 5 to30% by weight of an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid, (ii)'" 0.5 to 10% byweight of an α,β-monoethylenically unsaturated carboxylic acid and(ii)"" 60 to 90% by weight of a copolymerizable α,β-monoethylenicallyunsaturated monomer other than said monomers (iv) and (ii)'".
 10. Anaqueous dispersion type thermosetting coating composition whichcomprises (A) fine water-insoluble thermosetting resin particlesconsisting essentially of (a) 15 to 95% by weight of a preformedpolyester-modified vinyl resin having a hydroxyl value of 10 to 150,which is formed by solution graft-polymerizing (i) 2 to 40% by weight ofan unsaturated polyester resin formed by .[.reaction between an.]..Iadd.reacting 1-10% by weight of at least one α,β-.Iaddend.unsaturateddicarboxylic acid.Iadd., at least one carboxylic acid component selectedfrom the group consisting of phthalic acid, phthalic anhydride,isophthalic acid, isophthalic anhydride, trimellitic acid, trimelliticanhydride, pyromellitic acid, pyromellitic anhydride, tetrahydrophthalicacid, tetrahydrophthalic anhydride, hexahydrophthalic acid,hexahydrophthalic anhydride, methylhexahydrophthalic acid,methylhexahydrophthalic anhydride, 3,6-endomethylene-tetrahydrophthalicanhydride, succinic acid, succinic anhydride, adipic acid, sebacic acid,benzoic acid and p-tert-butyl-benzoic acid .Iaddend.and .[.a.]. .Iadd.atleast one .Iaddend.polyhydric alcohol with 98 to 60% by weight of amonomer mixture comprising (iv) an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide and (ii) atleast one α,β-monoethylenically unsaturated monomer and (b) 85 to 5% byweight of a preformed phosphoric acid group-containing copolymer resinderived from a monomer mixture comprising (iii) a phosphoric acidgroup-containing α,β-monoethylenically unsaturated monomer and (ii) atleast one α,β-monoethylenically unsaturated monomer, (B) a surfaceactive agent and/or a thickener in an amount of 0.01 to 1.0% by weightbased on said resin particles and (C) a necessary amount of water..[.11. An aqueous dispersion type thermosetting coating composition asset forth in claim 10 wherein said unsaturated polyester resin comprises1 to 10% by weight of at least one α,β-unsaturated dicarboxylic acid asone constituent..].
 12. An aqueous dispersion type thermosetting coatingcomposition as set forth in claim 10 where the α,β-monoethylenicallyunsaturated monomer mixture graft-polymerized with said unsaturatedpolyester resin comprises (ii)' 1 to 30% by weight of a hydroxyalkylester of an α,β-monoethylenically unsaturated carboxylic acid, (iv) 5 to30% by weight of an N-alkoxymethylated monomer of anα,β-monoethylenically unsaturated carboxylic acid amide and (ii)" 60 to90% by weight of a copolymerizable α,β-monoethylenically unsaturatedmonomer other than said monomers (iv) and (ii)'.
 13. An aqueousdispersion type thermosetting coating composition as set forth in claim10 wherein said phosphoric acid group-containing copolymer resin isderived from a monomer mixture comprising (iii) 0.01 to 10% by weight ofa phosphoric acid group-containing α,β-monoethylenically unsaturatedmonomer, (ii)'" 0.5 to 10% by weight of an α,β-monoethylenicallyunsaturated carboxylic acid, (ii)' 1 to 30% by weight of a hydroxyalkylester of an α,β-monoethylenically unsaturated carboxylic acid and (ii)"70 to 90% by weight of a copolymerizable α,β-monoethylenicallyunsaturated monomer other than said monomers (iii), (ii)'" and (ii)'..Iadd.14. An aqueous dispersion type thermosetting coating compositionas set forth in claim 1 wherein 30-70% by weight of the polyhydricalcohol is reacted. .Iaddend. .Iadd.15. An aqueous dispersion typethermosetting coating composition as set forth in claim 14 wherein29-69% by weight of said carboxylic acid component is reacted. .Iaddend..Iadd.16. An aqueous dispersion type thermosetting coating compositionas set forth in claim 14, wherein said (A) fine water-insolublethermosetting resin particles consist essentially of 5 to 90% by weightof said polyester-modified vinyl resin having a hydroxyl value of 30 to200, which is formed by solution graft-polymerizing (i) 5 to 50% byweight of said unsaturated polyester resin with (ii) 95 to 50% by weightof at least one said α,β-monoethylenically unsaturated monomer and 95 to10% by weight of said cross-linkable copolymer resin, and said (B)surface active agent and/or thickener is present in an amount of 0.01 to1.0% by weight based on said resin particles. .Iaddend. .Iadd.17. Anaqueous dispersion type thermosetting coating composition as set forthin claim 14 wherein the α,β-monoethylenically unsaturated monomergraft-polymerized with said unsaturated polyester resin is a monomermixture comprising (ii)' 5 to 50% by weight of a hydroxyalkyl ester ofan α,β-monoethylenically unsaturated carboxylic acid and (ii)" 95 to 50%by weight of a copolymerizable α,β-monoethylenically unsaturated monomerother than said monomer (ii)'. .Iaddend. .Iadd.18. An aqueous dispersiontype thermosetting coating composition as set forth in claim 14 whereinsaid cross-linkable copolymer resin is derived from a monomer mixturecomprising (iv) 5 to 30% by weight of an N-alkoxymethylated monomer ofan α,β-monoethylenically unsaturated carboxylic acid amide, (ii)"' 0.5to 10% by weight of an α,β-monoethylenically unsaturated carboxylic acidand (ii)"" 60 to 90% by weight of a copolymerizableα,β-monoethylenically unsaturated monomer other than said monomers (iv)and (ii)"'. .Iaddend. .Iadd.19. An aqueous dispersion type thermosettingcoating composition as set forth in claim 14 wherein said (A) finewater-insoluble thermosetting resin particles consist essentially of (a)5 to 90% by weight of said polyester-modified vinyl resin having ahydroxy value of 30 to 200, which is formed by solutiongraft-polymerizing (i) 2 to 50% by weight of said unsaturated polyesterresin with (ii) 95 to 40% by weight of at least one saidα,β-monoethylenically unsaturated monomer and (iii) 0.01 to 10% byweight of said phosphoric acid group-containing α,β-monoethylenicallyunsaturated monomer and (b) 95 to 10% by weight of said cross-linkablecopolymer resin, and said (B) surface active agent and/or thickener ispresent in an amount of 0.01 to 1.0% by weight based on said resinparticles. .Iaddend. .Iadd.20. An aqueous dispersion type thermosettingcoating composition as set forth in claim 15 wherein said (A) finewater-insoluble thermosetting resin particles consist essentially of 5to 90% by weight of said polyester-modified vinyl resin having ahydroxyl value of 30 to 200, which is formed by solutiongraft-polymerizing (i) 5 to 50% by weight of said unsaturated polyesterresin with (ii) 95 to 50% by weight of at least one saidα,β-monoethylenically unsaturated monomer and 95 to 10% by weight ofsaid cross-linkable copolymer resin, and said (B) surface active agentand/or thickener is present in an amount of 0.01 to 1.0% by weight basedon said resin particles. .Iaddend. .Iadd.21. An aqueous dispersion typethermosetting coating composition as set forth in claim 15 wherein theα,β-monoethylenically unsaturated monomer graft-polymerized with saidunsaturated polyester resin is a monomer mixture comprising (ii)' 5 to50% by weight of a hydroxyalkyl ester of an α,β-monoethylenicallyunsaturated carboxylic acid and (ii)" 95 to 50% by weight of acopolymerizable α,β-monoethylenically unsaturated monomer other thansaid monomer (ii)'. .Iaddend. .Iadd.22. An aqueous dispersion typethermosetting coating composition as set forth in claim 15 wherein saidcross-linkable copolymer resin is derived from a monomer mixturecomprising (iv) 5 to 30% by weight of an N-alkoxymethylated monomer ofan α,β-monoethylenically unsaturated carboxylic acid amide, (ii)"' 0.5to 10% by weight of an α,β-monoethylenically unsaturated carboxylic acidand (ii)"" 60 to 90% by weight of a copolymerizableα,β-monoethylenically unsaturated monomer other than said monomers (iv)and (ii)"'. .Iaddend. .Iadd.23. An aqueous dispersion type thermosettingcoating composition as set forth in claim 15 wherein said (A) finewater-insoluble thermosetting resin particles consist essentially of (a)5 to 90% by weight of said polyester-modified vinyl resin having ahydroxy value of 30 to 200, which is formed by solutiongraft-polymerizing (i) 2 to 50% by weight of said unsaturated polyesterresin with (ii) 95 to 40% by weight of at least one saidα,β-monoethylenically unsaturated monomer and (iii) 0.01 to 10% byweight of said phosphoric acid group-containing α,β-monoethylenicallyunsaturated monomer and (b) 95 to 10% by weight of said cross-linkablecopolymer resin, and said (B) surface active agent and/or thickener ispresent in an amount of 0.01 to 1.0% by weight based on said resinparticles. .Iaddend. .Iadd.24. An aqueous dispersion type thermosettingcoating composition as set forth in claim 19, wherein theα,β-monoethylenically unsaturated monomer graft-polymerized with saidunsaturated polyester resin is a monomer mixture comprising (ii)' 1 to40% by weight of a hydroxyalkyl ester of an α,β-monoethylenicallyunsaturated carboxylic acid and (ii)" 99 to 60% by weight of acopolymerizable α,β-monoethylenically unsaturated monomer other thansaid monomer (ii)'. .Iaddend. .Iadd.25. An aqueous dispersion typethermosetting coating composition as set forth in claim 19 wherein saidcross-linkable copolymer resin is derived from a monomer mixturecomprising (iv) 5 to 30% by weight of an N-alkoxymethylated monomer ofan α,β-monoethylenically unsaturated carboxylic acid, (ii)"' 0.5 to 10%by weight of an α,β-monoethylenically unsaturated carboxylic acid and(ii)"" 60 to 90% by weight of a copolymerizable α,β-monoethylenicallyunsaturated monomer other than said monomers (iv) and (ii)'". .Iaddend..Iadd.26. An aqueous dispersion type thermosetting coating compositionas set forth in claim 23 wherein the α,β-monoethylenically unsaturatedmonomer graft-polymerized with said unsaturated polyester resin is amonomer mixture comprising (ii)' 1 to 40% by weight of a hydroxyalkylester of an α,β-monoethylenically unsaturated carboxylic acid and (ii)'99 to 66% by weight of a copolymerizable α,β-monoethylenicallyunsaturated monomer other than said monomer (ii)'. .Iaddend. .Iadd.27.An aqueous dispersion type thermosetting coating composition as setforth in claim 23 wherein said cross-linkable copolymer resin is derivedfrom a monomer mixture comprising (iv) 5 to 30% by weight of anN-alkoxymethylated monomer of an α,β-monoethylenically unsaturatedcarboxylic acid, (ii)"' 0.5 to 10% by weight of an α,β-monoethylenicallyunsaturated carboxylic acid and (ii)"" 60 to 90% by weight of acopolymerizable α,β-monoethylenically unsaturated monomer other thansaid monomers (iv) and (ii)'". .Iaddend. .Iadd.28. An aqueous dispersiontype thermosetting coating composition as set forth in claim 10 wherein30-70% by weight of the polyhydric alcohol is reacted. .Iaddend..Iadd.29. An aqueous dispersion type thermosetting coating compositionas set forth in claim 28 wherein 29-69% by weight of said carboxylicacid component is reacted. .Iaddend. .Iadd.30. An aqueous dispersiontype thermosetting coating composition as set forth in claim 28 whereinthe α,β-monoethylenically unsaturated monomer mixture graft-polymerizedwith said unsaturated polyester resin comprises (ii)' 1 to 30% by weightof a hydroxyalkyl ester of an α,β-monoethylenically unsaturatedcarboxylic acid, (iv) 5 to 30% by weight of an N-alkoxymethylatedmonomer of an α,β-monoethylenically unsaturated carboxylic acid amideand (ii)" 60 to 90% by weight of a copolymerizable α,β-monoethylenicallyunsaturated monomer other than said monomers (iv) and (ii)". .Iaddend..Iadd.31. An aqueous dispersion type thermosetting coating compositionas set forth in claim 29 wherein the α,β-monoethylenically unsaturatedmonomer mixture graft-polymerized with said unsaturated polyester resincomprises (ii)' 1 to 30% by weight of a hydroxyalkyl ester of anα,β-monoethylenically unsaturated carboxylic acid, (iv) 5 to 30% byweight of an N-alkoxymethylated monomer of an α,β-monoethylenicallyunsaturated carboxylic acid amide and (ii)" 60 to 90% by weight of acopolymerizable α,β-monoethylenically unsaturated monomer other thansaid monomers (iv) and (ii)". .Iaddend. .Iadd.32. An aqueous dispersiontype thermosetting coating as set forth in claim 28 wherein saidphosphoric acid group-containing copolymer resin is derived from amonomer mixture comprising (iii) 0.01 to 10% by weight of a phosphoricacid group-containing α,β-monoethylenically unsaturated monomer, (ii)"'0.5 to 10% by weight of an α,β-monoethylenically unsaturated carboxylicacid, (ii)' 1 to 30% by weight of a hydroxyalkyl ester of anα,β-monoethylenically unsaturated carboxylic acid and (ii)" 70 to 90% byweight of a copolymerizable α,β-monoethylenically unsaturated monomerother than said monomers (iii), (ii)'" and (ii)'. .Iaddend. .Iadd.33. Anaqueous dispersion type thermosetting coating composition as set forthin claim 29 wherein said phosphoric acid group-containing copolymerresin is derived from a monomer mixture comprising (iii) 0.01 to 10% byweight of a phosphoric acid group-containing α,β-monoethylenicallyunsaturated monomer, (ii)"' 0.5 to 10% by weight of anα,β-monoethylenically unsaturated carboxylic acid, (ii)' 1 to 30% byweight of a hydroxyalkyl ester of an α,β-monoethylenically unsaturatedcarboxylic acid and (ii)" 70 to 90% by weight of a copolymerizableα,β-monoethylenically unsaturated monomer other than said monomers(iii), (ii)'" and (ii)'. .Iaddend.